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 model of imperfect preventive maintenance with dependent failure modes

Consider a system subject to two modes of failures: maintainable and non-maintainable. A failure rate function is related to each failure mode. Whenever the system fails, a minimal repair is performed. Preventive maintenances are performed at integer multiples of a fixed period. The system is replaced when a fixed number of preventive maintenances have been completed. The preventive maintenance is imperfect because it reduces the failure rate of the maintainable failures but does not affect the failure rate of the non-maintainable failures. The two failure modes are dependent in the following way: after each preventive maintenance, the failure rate of the maintainable failures depends on the total of non-maintainable failures since the installation of the system. The problem is to determine an optimal length between successive preventive maintenances and the optimal number of preventive maintenances before the system replacement that minimize the expected cost rate. Optimal preventive maintenance schedules are obtained for non-decreasing failure rates and numerical examples for power law models are given.     

Age-reduction models for imperfect maintenance

Maintenance of a deteriorating system is often imperfect, withthe state of the system after maintenance being at a level somewherebetween new and its prior condition.In this paper, the conceptof reduction in virtual or effective age is used to model theeffect of both imperfect corrective maintenance (CM) and imperfectpreventive maitnenance (PM). Results from counting-process theorythen produce a likelihood function necessary for parameter estimation,and the method is tested on known maintenance data. Finally,it is shown how to evaluate, by simulation, the expected numberofsystem failures up to time t under a given periodic PM strategy.This measure is incorporated into a cost rate function whichis then minimized to find the optimal length of a PM intervaland the optimal number of PMs to carry out before system replacement     

Maintenance optimization for second‐hand products following periodic imperfect preventive maintenance warranty period

The maintenance policy for a product's life cycle differs for second‐hand and new products. Although several maintenance policies for second‐hand products exist in the literature, they are rarely investigated with reference to periodic inspection and preventive maintenance action during the warranty period. In this research, we study an optimal post‐warranty maintenance policy for a second‐hand product, which was purchased at age x with a fixed‐length warranty period. During the warranty period, the product is periodically inspected and maintained preventively at a prorated cost borne by the user, while any product failure is only minimally repaired by the dealer. After the warranty expires, the product is self‐maintained by the user for a fixed‐length maintenance period and the costs incurred during this time are fully borne by the user. At the end of the maintenance period, the product is replaced with a product of the user's choice. This study is focused on the determination of an optimal length for the maintenance period after the warranty expiration. As a criterion for the optimality, we adopt the long‐run mean cost during the second‐hand product's life cycle from the user's perspective. Finally, our results are analyzed numerically for sensitive analysis of several relevant factors, assuming that the failure distribution follows a Weibull distribution.     

Optimal economic production quantity policy for imperfect process with imperfect repair and maintenance

This study integrates maintenance and production programs with the economic production quantity (EPQ) model for an imperfect process involving a deteriorating production system with increasing hazard rate: imperfect repair and rework upon failure (out of control state). The imperfect repair performs some restorations and restores the system to an operating state (in-control state), but leaves its failure until perfect preventive maintenance (PM) is performed. There are two types of PM, namely imperfect PM and perfect PM. The probability that perfect PM is performed depends on the number of imperfect maintenance operations performed since the last renewal cycle. Mathematical formulas are obtained for deriving the expected total cost. For the EPQ model, the optimum run time, which minimizes the total cost, is discussed. Various special cases are considered, including the maintenance learning effect. Finally, a numerical example is presented to illustrate the effects of PM, setup, breakdown and holding costs.     

Condition-based maintenance with imperfect inspections for continuous degradation processes

A condition-based maintenance (CBM) strategy is now recognized as an efficient approach to perform maintenance at the best time before failures so as to save lifetime cycle cost. For continuous degradation processes, a significant source of variability lies in measurement errors caused by imperfect inspections, and this may lead to “false positive” or “false negative” observations, and consequently to inopportune maintenance decisions. To the best of our knowledge, researches on CBM optimization with imperfect inspections remain limited for continuous degradation processes, even though the subject is of practical interest for the implementation of a CBM policy. Imperfect inspections are indeed imperfect but still return interesting information on the system degradation level, and making them perfect can be expensive. Therefore, we analyze the economic performance of a maintenance policy with imperfect inspections, and compare it with the classical policy with perfect inspections to see which policy offers the best benefit in a given situation. Furthermore, a CBM policy with a two-stage inspection scheme is proposed to take benefit of mixing both perfect and imperfect inspections in the same maintenance policy. Through numerical experiments and a real case study, it is shown that the policy with imperfect inspections can be better than the classical one, and that the proposed policy with a two-stage inspection scheme always leads to the minimum long run maintenance cost rate.     

An imperfect maintenance model with block replacements

We consider a model in which when a device fails it is either repaired to its condition prior to failure or replaced. Moreover, the device is replaced at times kT, k = 1, 2, … The decision to repair or replace the device at failure depends on the age of the device at failure. We find the optimal block time, T₀, that minimizes the long-run average cost of maintenance per unit time. Our results are shown to extend many of the well known results for block replacement policies.     

Degradation-based burn-in with preventive maintenance

As many products are becoming increasingly more reliable, traditional lifetime-based burn-in approaches that try to fail defective units during the test require a long burn-in duration, and thus are not effective. Therefore, we promote the degradation-based burn-in approach that bases the screening decision on the degradation level of a burnt-in unit. Motivated by the infant mortality faced by many Micro-Electro-Mechanical Systems (MEMSs), this study develops two degradation-based joint burn-in and maintenance models under the age and the block based maintenances, respectively. We assume that the product population comprises a weak and a normal subpopulations. Degradation of the product follows Wiener processes with linear drift, while the weak and the normal subpopulations possess distinct drift parameters. The objective of joint burn-in and maintenance decisions is to minimize the long run average cost per unit time during field use by properly choosing the burn-in settings and the preventive replacement intervals. An example using the MEMS devices demonstrates effectiveness of these two models.     

A novel repair model for imperfect maintenance

^** Email: shaomin.wu{at}reading.ac.uk Commonly used repair rate models for repairable systems in thereliability literature are renewal processes, generalised renewalprocesses or non-homogeneous Poisson processes. In additionto these models, geometric processes (GP) are studied occasionally.The GP, however, can only model systems with monotonously changing(increasing, decreasing or constant) failure intensities. Thispaper deals with the reliability modelling of failure processesfor repairable systems where the failure intensity shows a bathtub-typenon-monotonic behaviour. A new stochastic process, i.e. an extendedPoisson process, is introduced in this paper. Reliability indicesare presented, and the parameters of the new process are estimated.Experimental results on a data set demonstrate the validityof the new process.     

On a software availability model with imperfect maintenance

In this paper we consider a general software availability model and derive compound availability measures, such as the joint probability of software availability and the remaining number of errors. The results given here generalize the results given in Kim et al. (1982).     

Optimal threshold values of age and two-phase maintenance policy for leased equipments using age reduction method

This paper investigates the optimal threshold values of age to perform preventive maintenance (PM) actions for leased equipment within the lease period. In this paper, we use age reduction method to describe the degree of PM and construct the maintenance cost function. For repairable leased equipment, two maintenance models are proposed: (i) maintenance policy of single-phase and (ii) maintenance policy of two-phase. During the lease period, PM actions are carried out when the age of equipment reaches a certain threshold value. Any failure of the leased equipment is rectified by a minimal repair within the lease period. Under these maintenance schemes, the mathematical models of the expected total cost for maintenance policies of single-phase and two-phase are established, and the optimal maintenance policies are derived such that the expected total cost is minimized. Finally, the features of the optimal maintenance policy are illustrated through numerical examples.     

Optimal production correction and maintenance policy for imperfect process

This study considers imperfect production processes that require production correction and maintenance. Two states of the production process are performed, namely: the type I state (out-of-control state) and the type II state (in-control state). At the beginning of the production of the each renewal cycle, the state of the process is assumed not always to be restored to “in-control”. The type I state involves the adjustment of the production mechanism, whereas the type II state does not. Production correction is either imperfect; worsening a production system, or perfect, returning it to “in-control”. After N + 1 type I states, the operating system must be maintained and returned to the beginning condition. The mean loss cost due to reproduction through production correction per the total expected cost until the N + 1 type I states are entered successively is determined. The existence of a unique and finite optimal N for an imperfect process under certain reasonable conditions is shown. A numerical example is presented.     

Modelling preventive maintenance for deteriorating repairable systems

This paper is concerned with practical methods for the analysisand modelling of data for repairable systems which are subjectto preventive maintenance (PM) and still have an increasingrate of occurrence of failures. Aspects of testing for trendand fitting a nonhomogeneous Poission process to data are discussedModels for scheduling preventive maintenance to minimize costor maximize availability are proposed. They show that the optimalPM cycle interval for these systems decreases with increasingequipment age. One-cycle and two-cycle finite-time-zone replacementmodels are also developed to decide the optimal time for replacingthe equipment in current use.     

A hybrid maintenance model with imperfect inspection for a system with deterioration and Poisson failure

A new maintenance model for a system with both deterioration and Poisson failures is proposed. In this model, at any time-instant G _S and when the system is operating, one of the following decisions may be taken: (1) stop the system to perform a scheduled minimal maintenance; (2) stop the system to perform an inspection; and (3) no action and allow the system to go on with its operation. Following an inspection, based on the deterioration condition of the system, one of the following decisions may be taken: (a) if the system is in a ‘good’ condition, no maintenance action is taken and a number of periodic minimal maintenance activities are scheduled, starting T1 later; (b) if the system is in an ‘intermediate’ condition, a minimal maintenance is performed and an inspection is scheduled for T2 later (T2 < T1); and (c) if the system is in a ‘bad’ condition, a major maintenance is performed and a number of periodic minimal maintenances are scheduled, starting T1 later. In addition, a deterioration failure is restored by a major repair and a Poisson failure is restored by a minimal repair. Generalised stochastic Petri nets are used to represent and analyse the model, which represents a ‘composite’ maintenance strategy. Based on maximisation of the throughput of the system the benefit of this model compared to (1) an equivalent periodic inspection model and (2) an equivalent planned scheduled maintenance model, is demonstrated. This study presents a new hybrid model with a general framework for incorporating various types of maintenance policies. Also by incorporation of a number of features, this model will be more applicable to real world technical systems (complex systems), although it can be applied to individual components that are part of a complex system.     

A geometric process maintenance model with preventive repair

In this paper, a geometric process maintenance model with preventive repair is studied. A maintenance policy (T, N) is applied by which the system will be repaired whenever it fails or its operating time reaches T whichever occurs first, and the system will be replaced by a new and identical one following the Nth failure. The long-run average cost per unit time is determined. An optimal policy (T^∗, N^∗) could be determined numerically or analytically for minimizing the average cost. A new class of lifetime distribution which takes into account the effect of preventive repair is studied that is applied to determine the optimal policy (T^∗, N^∗).     

Condition-based maintenance policies under imperfect maintenance at scheduled and unscheduled opportunities

Queueing Systems - Motivated by the cost savings that can be obtained by sharing resources in a network context, we consider a stylized, yet representative, model for the coordination of...     

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.     

Scheduling preventive railway maintenance activities

A railway system needs a substantial amount of maintenance. To prevent unexpected breakdowns as much as possible, preventive maintenance is required. In this paper we discuss the preventive maintenance scheduling problem (PMSP), where (short) routine activities and (long) unique projects have to be scheduled in a certain period. To reduce costs and inconvenience for the travellers and operators, these activities should be scheduled together as much as possible. We present two versions of the PMSP, one with fixed intervals between two consecutive executions of the same routine work, and one with only a maximum interval. Apart from giving a math programming formulation for the PMSP and for its extension we also present some heuristics. In addition, we compare the performance of these heuristics with the optimal solution using some randomly generated instances.     

An optimal maintenance policy for skipping imminent preventive maintenance for systems experiencing random failures

In this study we investigate systems that experience random failures and establish decision rules for performing renewal maintenance; that is, a preventive replacement (PR) policy. We seek a policy that is both simple to execute from the point of view of the maintenance planner but also a policy that is an improvement on existing schemes. We show that our policy is a hybrid of traditional time-based and age-based schemes and one that yields considerable cost savings. Our hybrid policy involves two decision variables. One decision variable is the time between PRs. Hence, for the maintenance planner, the times at which PRs are performed are chronologically fixed. Random failures can occur, however, and the machine receives an emergency renewal (ER) at these times. Hence, within these chronological times, a second decision time is identified. Should an ER occur between the start of a cycle and this second decision time, then the planned PR would still be performed at the end of the cycle. However, if the first ER occurs after this second decision time, then the PR at the end of the cycle is skipped over and the next planned PR would take place at the end of the subsequent cycle. With this simple mechanism, PRs that follow on too closely after an ER are avoided, thus saving the unnecessary expense. Numerical examples are given to examine the validity of the model, using four different failure density functions, namely Weibull, normal, uniform, and negative exponential.     

Searching for multiobjective preventive maintenance schedules: Combining preferences with evolutionary algorithms

Heavy industry maintenance facilities at aircraft service centers or railroad yards must contend with scheduling preventive maintenance tasks to ensure critical equipment remains available. The workforce that performs these tasks are often high-paid, which means the task scheduling should minimize worker idle time. Idle time can always be minimized by reducing the workforce. However, all preventive maintenance tasks should be completed as quickly as possible to make equipment available. This means the completion time should be also minimized. Unfortunately, a small workforce cannot complete many maintenance tasks per hour. Hence, there is a tradeoff: should the workforce be small to reduce idle time or should it be large so more maintenance can be performed each hour? A cost effective schedule should strike some balance between a minimum schedule and a minimum size workforce.