Optimum policy for a production system with major repair and preventive maintenance

This study applies periodic preventive maintenance (PM) to a repairable production system with major repairs conducted after a failure. This study considers failed PM due to maintenance workers incorrectly performing PM and damages occurring after PM. Therefore, three PM types are considered: imperfect PM, perfect PM and failed PM. Imperfect PM has the same failure rate as that before PM, whereas perfect PM makes restores the system perfectly. Failed PM results in system deterioration and major repairs are required. The probability that PM is perfect or failed depends on the number of imperfect maintenance operations conducted since the previous renewal cycle. Mathematical formulas for expected total production cost per unit time are generated. Optimum PM time that minimizes cost is derived. Various special cases are considered, including the maintenance learning effect. A numerical example is given.     

Age-dependent production planning and maintenance strategies in unreliable manufacturing systems with lost sale

In this paper, we formulate an analytical model for the joint determination of an optimal age-dependent buffer inventory and preventive maintenance policy in a production environment that is subject to random machine breakdowns. Traditional preventive maintenance policies, such as age and periodic replacements, are usually studied based on simplified and non-realistic assumptions, as well as on the expected costs criterion. Finished goods inventories and the age-dependent likelihood of machine breakdowns are usually not considered. As a result, these policies could significantly extend beyond the anticipated financial incomes of the system, and lead to crises. In order to solve this problem, a more realistic analysis model is proposed in this paper to consider the effects of both preventive maintenance policies and machine age on optimal safety stock levels. Hence, a unified framework is developed, allowing production and preventive maintenance to be jointly considered. We use an age-dependent optimization model based on the minimization of an overall cost function, including inventory holdings, lost sales, preventive and corrective maintenance costs. We provide optimality conditions for the manufacturing systems considered, and use numerical methods to obtain an optimal preventive maintenance policy and the relevant age-dependent threshold level production policy. In this work, this policy is called the multiple threshold levels hedging point policy. We include numerical examples and sensitivity analyses to illustrate the importance and the effectiveness of the proposed methodology. Compared with other available optimal production and maintenance policies, the numerical solution obtained shows that the proposed age-dependent optimal production and maintenance policies significantly reduce the overall cost incurred.     

Economic production lot-sizing for an unreliable machine under imperfect age-based maintenance policy

This paper is concerned with the joint determination of both economic production quantity and preventive maintenance (PM) schedules under the realistic assumption that the production facility is subject to random failure and the maintenance is imperfect. The manufacturing system is assumed to deteriorate while in operation, with an increasing failure rate. The system undergoes PM either upon failure or after having reached a predetermined age, whichever of them occurs first. As is often the case in real manufacturing applications, maintenance activities are imperfect and unable to restore the system to its original healthy state. In this work, we propose a model that could be used to determine the optimal number of production runs and the sequence of PM schedules that minimizes the long-term average cost. Some useful properties of the cost function are developed to characterize the optimal policy. An algorithm is also proposed to find the optimal solutions to the problem at hand. Numerical results are provided to illustrate both the use of the algorithm in the study of the optimal cost function and the latter’s sensitivity to different changes in cost factors.     

A novel optimal preventive maintenance policy for a cold standby system based on semi-Markov theory

A novel optimal preventive maintenance policy for a cold standby system consisting of two components and a repairman is described herein. The repairman is to be responsible for repairing either failed component and maintaining the working components under certain guidelines. To model the operational process of the system, some reasonable assumptions are made and all times involved in the assumptions are considered to be arbitrary and independent. Under these assumptions, all system states and transition probabilities between them are analyzed based on a semi-Markov theory and a regenerative point technique. Markov renewal equations are constructed with the convolution of the cumulative distribution function of system time in each state and corresponding transition probability. By using the Laplace transform to solve these equations, the mean time from the initial state to system failure is derived. The optimal preventive maintenance policy that will provide the optimal preventive maintenance cycle is identified by maximizing the mean time from the initial state to system failure, and is determined in the form of a theorem. Finally, a numerical example and simulation experiments are shown which validated the effectiveness of the policy.     

Availability analysis of crank-case manufacturing in a two-wheeler automobile industry

The paper describes the availability of crank-case manufacturing system in an automobile industry. The units discussed here fail either directly from normal working state or indirectly through partial failure state. The machines are subjected to both preventive and corrective maintenance. Failure and repair times of the units are independent. The problem is formulated using probability consideration and supplementary variable technique. The system of equations governing the working of system consists of ordinary as well as partial differential equations. Lagrange method and Runge–Kutta method is used to solve partial differential equation and ordinary differential equation respectively. The study reveals that successful program of preventive and routine maintenance will reduce equipment failures, extend the life of the equipment, and increase the system availability to considerable margin.     

Data-driven preventive maintenance for a heterogeneous machine portfolio

We describe a data-driven approach to optimize periodic maintenance policies for a heterogeneous portfolio with different machine profiles. When insufficient data are available per profile to assess failure intensities and costs accurately, we pool the data of all machine profiles and evaluate the effect of (observable) machine characteristics by calibrating appropriate statistical models. This reduces maintenance costs compared to a stratified approach that splits the data into subsets per profile and a uniform approach that treats all profiles the same.     

Ant colony optimization for power plant maintenance scheduling optimization—a five-station hydropower system

A number of algorithms have been developed for the optimization of power plant maintenance schedules. However, the true test of such algorithms occurs when they are applied to real systems. In this paper, the application of an Ant Colony Optimization formulation to a hydropower system is presented. The formulation is found to be effective in handling various constraints commonly encountered in practice. Overall, the results obtained using the ACO formulation are better than those given by traditional methods using engineering judgment, which indicates the potential of ACO in solving realistic power plant maintenance scheduling problems.     

MUT of a one out of two system with preventive maintenance

We are interested in the MUT (Mean Up Time) of a one out of two system in cold standby with preventive maintenance: a preventive maintenance occurs when the working unit reaches a given age. We study in details the stationary distribution of the Markov chain describing the state of the system at the beginning of its working periods. We give exact analytical formulas from which we derive a way to compute the MUT and we compare the results with those of Smith and Decker [M.A.J. Smith, R. Decker, Preventive maintenance in a 1 out of n system: The uptime, downtime and costs, European Journal of Operational Research 99 (1997) 565–583] which are based on approximations. We also investigate some discontinuities problems.     

An optimal age maintenance for an M/G/1 queueing system

This paper discusses an optimal age maintenance scheme for a queueing system. Customers arrive at the system according to a Poisson process. They form a single queue and are served by a server with general service distribution. The system fails after a random time and corrective maintenance is performed at the failure. A preventive maintenance is also performed if the system is empty at age T where ‘age’ refers to the elapsed time since the previous maintenance was completed. If the system is not empty at age T, the system is used until it fails. At the failure, the customers in the system are lost and the arriving customers during the maintenance are also lost. By renewal theory, we study the optimal value of T which minimizes the average number of lost customers over an infinite time horizon.     

On optimization of the maintenance of a register

Data processing nowadays represents a considerable investment and it is important to use computers as efficiently as possible. Criteria separating the best alternative from other ones would be very useful.In this article we have tried to find some criteria for the optimization of register maintenance applying the simplest methods of operations research. In particular the use of a change register has been investigated.     

Financial planning for the preventive maintenance of power distribution systems via fuzzy AHP

One of the most important objectives of electricity distribution companies is to improve the reliability of the distribution networks. To this end, the electricity distribution companies try to optimally use the existing financial resources in the planning of preventive maintenance (PM) programs to reduce the imposed costs on the system due to the failure of network components and to improve the network reliability. In fuzzy analytical hierarchical process (fuzzy AHP) method, the degree of network reliability and the effectiveness of PM budget in the improvement of network reliability are selected as decision criteria in the budget allocation procedure. The areas served by the power distribution network are prioritized relative to each other and are assigned weights based on these priorities. The PM budget is determined based on the obtained weights. The medium voltage distribution network of seven areas in the city of Tehran have been selected for the implementation of the proposed method and the analysis of the obtained results. © 2014 Wiley Periodicals, Inc. Complexity 21: 36–46, 2016     

A simulation optimization approach for a two-echelon inventory system with service level constraints

In this paper, we present a simulation optimization algorithm for solving the two-echelon constrained inventory problem. The goal is to determine the optimal setting of stocking levels to minimize the total inventory investment costs while satisfying the expected response time targets for each field depot. The proposed algorithm is more adaptive than ordinary optimization algorithms, and can be applied to any multi-item multi-echelon inventory system, where the cost structure and service level function resemble what we assume. Empirical studies are performed to compare the efficiency of the proposed algorithms with other existing simulation algorithms.     

A numerical method to approximate optimal production and maintenance plan in a flexible manufacturing system

The simultaneous planning of the production and the maintenance in a flexible manufacturing system is considered in this paper. The manufacturing system is composed of one machine that produces a single product. There is a preventive maintenance plan to reduce the failure rate of the machine. This paper is different from the previous researches in this area in two separate ways. First, the failure rate of the machine is supposed to be a function of its age. Second, we assume that the demand of the manufacturing product is time dependent and its rate depends on the level of advertisement on that product. The objective is to maximize the expected discounted total profit of the firm over an infinite time horizon. In the process of finding a solution to the problem, we first characterize an optimal control by introducing a set of Hamilton–Jacobi–Bellman partial differential equations. Then we realize that under practical assumptions, this set of equations can not be solved analytically. Thus to find a suboptimal control, we approximate the original stochastic optimal control model by a discrete-time deterministic optimal control problem. Then proposing a numerical method to solve the steady state Riccati equation, we approximate a suboptimal solution to the problem.     

A note on the integrality gap of an ILP formulation for the periodic maintenance problem

We address the integrality gap of the integer linear program introduced by Grigoriev et al. (2006) [3] for the periodic maintenance problem. We prove that the integrality gap of this program is bounded by a constant.     

Availability optimization of systems subject to competing risk

This paper considers a competing risk (degradation and sudden failure) maintenance situation. A maintenance model and a repair cost model are presented. The degradation state of the units is continuously monitored. When either the degradation level reaches a predetermined threshold or a sudden failure occurs before the unit reaches the degradation threshold level, the unit is immediately repaired (renewed) and restored to operation. The subsequent repair times increase with the number of renewals. This process is repeated until a predetermined time is reached for preventive maintenance to be performed. The optimal maintenance schedule that maximizes the unit availability subject to repair cost constraint is determined in terms of the degradation threshold level and the time to perform preventive maintenance.     

Portfolio selection under strict uncertainty: A multi-criteria methodology and its application to the Frankfurt and Vienna Stock Exchanges

In modern portfolio theory, it is common practice to first compute the risk-reward efficient frontier and then to support an individual investor in selecting a portfolio that meets his/her preferences for profitability and risk. Potential flaws include (a) the assumption that past data provide sufficient evidence for predicting the future performances of the securities under consideration and (b) the necessity to mathematically determine or approximate the investor’s utility function. In this paper, we propose a methodology whose initial phase filters portfolios that are inefficient from a historical perspective. While this is consistent with traditional approaches, the second phase differs from the standard approach as it uses a decision table constructed by considering multiple scenarios assuming strict uncertainty. The table cells measure consequences by a multi-criteria linear performance index of simulated future returns, which avoids difficulties with performance ratios. The real world applicability is illustrated through two studies based on data from the stock exchanges in Frankfurt and Vienna.     

Reliability-based measures for a retrial system with mixed standby components

In this paper, we consider a retrial and repairable multi-component system with mixed warm and cold standby components. It is assumed that the failure times of primary (operating) and warm standby components follow exponential distributions. When a component fails, it is sent to a service station with a single server (repairman) and no waiting space. The failed component is repaired if the server is idle and it has to enter an orbit if the server is busy. The failed component in the orbit will try to get the repair service again after an exponentially distributed random time period. The repair time also has an exponential distribution. The mean time-to-failure, MTTF, and the steady-state availability, A_T(∞), are derived in this retrial and repairable system. Using a numerical example, we compare the systems with and without retrials in terms of the cost/benefit ratios. Sensitivity analysis for the mean time-to-failure and the steady-state availability are investigated as well.     

A Markov decision algorithm for optimal inspections and revisions in a maintenance system with partial information

This paper deals with a gradually deteriorating equipment whose actual degree of deterioration can be revealed by inspections only. An inspection can be succeeded by a revision depending on the system's degree of deterioration. In the absence of inspections and revisions, the working condition of the system evolves according to a Markov chain whose changes of state are not observable with the possible exception of a breakdown. Examples of this model include production machines subject to stochastic breakdowns, and maintenance of communication systems. The cost structure of the model consists of inspection, revision and operating costs. It is intuitively reasonable that in many applications a simple control-limit rule will be optimal. Such a rule prescribes a revision only when inspection reveals that the degree of deterioration has exceeded some critical level. A special-purpose Markov decision algorithm operating on the class of control-limit rules is developed for the computation of an average cost optimal schedule of inspections and revisions.     

On a single discrete scale for preventive maintenance with two shock processes affecting a complex system

A new approach to optimal maintenance of systems (networks) is suggested. It is applied to systems subject to two external independent shock processes. A system ‘consists’ of two parts, and each shock process affects only its own part. A new notion of bivariate signature is suggested and used for obtaining survival characteristics of a system and further optimization of the preventive maintenance actions. The preventive maintenance optimization is considered in the univariate discrete scale that counts the overall numbers of shocks of both types. An example of a transportation network is considered. Copyright © 2016 John Wiley & Sons, Ltd.