Optimal spare ordering policy for preventive replacement under cost effectiveness criterion

This paper presents a spare ordering policy for preventive replacement with age-dependent minimal repair and salvage value consideration. The spare unit for replacement is available only by order and the lead-time for delivering the spare due to regular or expedited ordering follows general distributions. To analyze the ordering policy, the failure process is modelled by a non-homogeneous Poisson process. By introducing the costs due to ordering, repairs, replacements and downtime, as well as the salvage value of an un-failed system, the expected cost effectiveness in the long run are derived as a criterion of optimality. It is shown, under certain conditions, there exists a finite and unique optimum ordering time which maximizes the expected cost effectiveness. Finally, numerical examples are given for illustration.     

An optimal ordering policy for a spare unit with lead time

We consider a generalised ordering policy in which a spare unit for replacement can be delivered only by order after a constant lead time. Introducing the costs for ordering, shortage and holding, we derive the expected cost per unit time in the steady-state. We discuss the optimal ordering policy which minimises the expected cost, and show in a main theorem that the optimal policy is reduced to either one of two typical ordering policies depending on some conditions. We further discuss a similar ordering policy with varying lead times.     

Optimal number of minimal repairs before ordering spare for preventive replacement

This paper presents a model for determining the optimal number of minimal repairs before ordering spare for preventive replacement. By introducing the costs of ordering, repair, downtime, replacement, and the salvage value of an un-failed system, the expected long-term cost rates and cost effectiveness are derived. It is shown that, under certain conditions, the optimal number of minimal repairs, which minimizes the cost rate or maximizes the cost effectiveness, is given by a unique solution of an equation. A numerical example is also given for illustration of the proposed model.     

Optimum ordering polices with the effect of weather condition,random lead times and salvage cost

In this paper we deal with an optimum ordering policy for a one-unit system with a general lifetime, where the failed unit is scrapped without repair. A spare can only be provided after a lead time. Two kinds of orders (regular and emergency) are possible, each having a different, generally distributed lead time. Weather conditions are subject to a Markov process with two states-normal and abnormal which has a constant rate λ from normal to abnormal weather condition and μ from abnormal to normal respectively. The operational status of the unit is affected by the abnormal weather condition. The costs include downtimes, salvage, penalty, ordering costs. The optimal policy discussed is the one which maximizes the cost effectiveness, and is illustrated with a numerical example     

A generalized discrete-time order replacement model

In this article, we consider a discrete-time order replacementproblem. More precisely, we treat a generalized model with morecomplex cost structure than Kaio & Osaki (1979, IEEE Trans.Reliab., R-29, 405–406) and with two decision variables:allowable inventory time and ordering time. Based on the discreteprobabilistic argument, we derive the optimal ordering policyto deliver a spare unit preventively by a regular order, soas to minimize the expected cost per unit time in the steadystate. Numerical examples are devoted to carrying out the sensitivityanalysis of model parameters on the optimal ordering policyand its associated expected cost value.     

考虑不完美检测的两阶段点检与备件订购策略联合优化

针对设备维修与备件管理相互影响与制约的问题, 在基于延迟时间理论的基础上, 提出了两阶段点检与备件订购策略联合优化。点检是不完美的, 当点检识别设备的缺陷状态时, 进行预防更新; 设备故障时, 进行故障更新。结合设备更新时备件的状态, 采用更新报酬理论建立了以第一阶段点检时间、第二阶段点检周期和备件订购时间为决策变量, 以最小化单位时间期望成本为目标的模型。最后, 通过人工蜂群算法对模型求解, 并在数值分析中将两阶段点检策略与定期点检策略进行比较, 结果表明:两阶段点检策略始终优于定期点检策略, 验证了所建模型的有效性。     

Joint optimization of spare parts ordering and maintenance policies for multiple identical items subject to silent failures

In this paper the joint maintenance and spare parts ordering problem for more than one identical operating items is studied. The operating items may suffer two types of silent failures: a minor failure, which results in item malfunctioning, and a major failure, which renders the item completely out-of-function. Inspections are periodically held to detect any failures and the inspected items are preventively maintained, repaired or replaced according to their condition. Two ordering policies are investigated to supply the necessary spare parts: a periodic review and a continuous review policy. The expected total maintenance and inventory cost per time unit is derived and the proposed models are optimized for real case data. In addition, the sensitivity of the proposed models is studied through numerical examples and the effect of some key problem characteristics on the optimal decisions is discussed.     

An efficient approach for solving the lot-sizing problem with time-varying storage capacities

We address the dynamic lot size problem assuming time-varying storage capacities. The planning horizon is divided into T periods and stockouts are not allowed. Moreover, for each period, we consider a setup cost, a holding unit cost and a production/ordering unit cost, which can vary through the planning horizon. Although this model can be solved using O(T³) algorithms already introduced in the specialized literature, we show that under this cost structure an optimal solution can be obtained in O(T log T) time. In addition, we show that when production/ordering unit costs are assumed to be constant (i.e., the Wagner–Whitin case), there exists an optimal plan satisfying the Zero Inventory Ordering (ZIO) property.     

Models for 1-out-of Q systems with stochastic lead times and expedited ordering options for spares inventory

The purpose of this article is to develop two kinds of continuous-time cyclic inventory models with stochastic lead times and expedited ordering options. The order form under consideration is similar to that arising in the spare part inventory management. Especially, the control problem to determine the timing for the regular order is considered, and the optimal policy which minimizes the long-run average cost is analytically characterized. Finally, numerical examples are presented to evaluate the uncertainty of stochastic lead times, and the optimal inventory policy, which is composed of both the ordering time and the order quantity, is numerically calculated.     

优化交货期窗口的两阶段供应链排序问题

研究一类优化交货期窗口的两阶段供应链排序问题. 优化交货期窗口是指交货期窗口的开始与结束时刻是决策变量, 不是输入常量. 两阶段是指工件先加工, 后运输: 加工阶段是一台加工机器逐个加工工件;运输阶段是无限台车辆分批运输完工的工件. 工件的开始运输时刻与完工时刻之差定义为工件的储存时间, 且有相应的储存费用. 若工件的运输完成时刻早于(晚于)交货期窗口的开始(结束)时刻, 则有相应的提前(延误)惩罚费用. 目标是极小化总提前惩罚费用、总延误惩罚费用、总储存费用、总运输费用以及与交货期窗口有关的费用之和. 针对单位时间的延误惩罚费用不超过单位时间的储存费用、单位时间的储存费用不超过单位时间的提前惩罚费用的情形, 给出了时间复杂性为O(n^{8})的动态规划算法.     

Reliability Analysis of a One-Unit System with Unrepairable Spare Units and its Optimization Applications

It is assumed that a unit is either in operation or is in repair. When the main unit is under repair, spare units which cannot be repaired are used. In this system the following quantities are of interest: (i) The time distribution and the mean time to first-system failure, given that the n spare units are provided at time 0. (ii) The probability that the number of the failed spare units are equal to exactly n during the interval (0, t], and its expected number during the interval (0, t]. These quantities are derived by solving the renewal-type equations.Two optimization problems are discussed using the results obtained, viz.: (i) The expected cost of two systems, one with both a main unit and spare units and the other with only spare units is considered. (ii) A preventive maintenance policy of the main unit is considered in order to minimize the expected cost rate. Some policies of the two problems are discussed under suitable conditions. Numerical examples are also presented.     

A number-dependent replacement policy for a system with continuous preventive maintenance and random lead times

This paper considers a number-dependent replacement policy for a system with two failure types that is replaced at the nth type I (minor) failure or the first type II (catastrophic) failure, whichever occurs first. Repair or replacement times are instantaneous but spare/replacement unit delivery lead times are random. Type I failures are repaired at zero cost since preventive maintenance is performed continuously. Type II failures, however, require costly system replacement. A model is developed for the average cost per unit time based on the stochastic behavior of the system and replacement, storage, and downtime costs. The cost-minimizing policy is derived and discussed. We show that the optimal number of type I failures triggering replacement is unique under certain conditions. A numerical example is presented and a sensitivity analysis is performed.     

A stochastic model for joint spare parts inventory and planned maintenance optimisation

Spare parts demands are usually generated by the need of maintenance either preventively or at failures. These demands are difficult to predict based on historical data of past spare parts usages, and therefore, the optimal inventory control policy may be also difficult to obtain. However, it is well known that maintenance costs are related to the availability of spare parts and the penalty cost of unavailable spare parts consists of usually the cost of, for example, extended downtime for waiting the spare parts and the emergency expedition cost for acquiring the spare parts. On the other hand, proper planned maintenance intervention can reduce the number of failures and associated costs but its performance also depends on the availability of spare parts. This paper presents the joint optimisation for both the inventory control of the spare parts and the Preventive Maintenance (PM) inspection interval. The decision variables are the order interval, PM interval and order quantity. Because of the random nature of plant failures, stochastic cost models for spare parts inventory and maintenance are derived and an enumeration algorithm with stochastic dynamic programming is employed for finding the joint optimal solutions over a finite time horizon. The delay-time concept developed for inspection modelling is used to construct the probabilities of the number of failures and the number of the defective items identified at a PM epoch, which has not been used in this type of problems before. The inventory model follows a periodic review policy but with the demand governed by the need for spare parts due to maintenance. We demonstrate the developed model using a numerical example.     

EOQ holds under stochastic demand,a technical note

We consider a variant of the economic order quantity (EOQ) model. Mainly, we assume that demand occurs at random, one unit at a time, and is characterized by independent and identically distributed times between two demand epochs. We also assume that the ordering policy is characterized by ordering the same amount whenever the inventory level drops to zero, and a demand occurs. Surprisingly, we show that the optimal order quantity that minimizes the expected inventory cost follows the familiar EOQ formula.     

储存时间有上限的两阶段供应链排序问题

研究一类储存时间有上限的两阶段供应链排序问题.两阶段是指工件先加工,后运输:加工阶段是一台加工机器逐个加工工件;运输阶段是无限台车辆分批运输完工的工件.工件的运输完成时刻与完工时刻之差定义为工件的储存时间,且有相应的储存费用,且任意工件的储存时间都不超过某一常数.若工件的运输完成时刻早于(晚于)交货期窗口的开始(结束)时刻,则有相应的提前(延误)惩罚费用.目标是极小化总提前惩罚费用、总延误惩罚费用、总储存费用、总运输费用以及与交货期窗口有关的费用之和.先证明该问题是NP-难的,后对单位时间的储存费用不超过单位时间的延误惩罚费用的情形给出了伪多项式时间算法.     

Wholesale price rebate vs. capacity expansion: The optimal strategy for seasonal products in a supply chain

We consider a supply chain in which one manufacturer sells a seasonal product to the end market through a retailer. Faced with uncertain market demand and limited capacity, the manufacturer can maximize its profits by adopting one of two strategies, namely, wholesale price rebate or capacity expansion. In the former, the manufacturer provides the retailer with a discount for accepting early delivery in an earlier period. In the latter, the production capacity of the manufacturer in the second period can be raised so that production is delayed until in the period close to the selling season to avoid holding costs. Our research shows that the best strategy for the manufacturer is determined by three driving forces: the unit cost of holding inventory for the manufacturer, the unit cost of holding inventory for the retailer, and the unit cost of capacity expansion. When the single period capacity is low, adopting the capacity expansion strategy dominates as both parties can improve their profits compared to the wholesale price rebate strategy. When the single period capacity is high, on the other hand, the equilibrium outcome is the wholesale price rebate strategy.     

Continuous-review,lost-sales inventory models with Poisson demand,a fixed lead time and no fixed order cost

This paper considers continuous-review lost-sales inventory models with no fixed order cost and a Poisson demand process. There is a holding cost per unit per unit time and a lost sales cost per unit. The objective is to minimise the long run total cost. Base stock policies are, in general, sub-optimal under lost sales. The optimal policy would have to take full account of the remaining lead times on all the orders currently outstanding and such a policy would be too complex to analyse, let alone implement. This paper considers policies which make use of the observation that, for lost sales models, base stock policies can be improved by imposing a delay between the placement of successive orders. The performance of these policies is compared with that of the corresponding base stock policy and also with the policy of ordering at fixed and regular intervals of time.     

顾客部分延期付款下两级商业信用易腐品订货策略

针对易腐品的经济订货批量问题展开研究。在供应商给零售商提供延迟还款的同时,零售商也给顾客提供部分延期还款条件。分五种情况分别讨论零售商的成本构成,并由此建立数学模型以求解最优订货周期使得零售商单位时间总成本最小化。通过数学证明得到了目标函数的解析性质,结果显示每种情况下在可行域范围内至多存在一个极小值点。以此为基础给出了相应的命题以有效地确定零售商的最优决策。最后通过数值算例说明了模型的有效性。     

碳交易规制下的制造商减排外包模式选择:定制vs订购?

研究碳交易规制下制造商减排服务外包时供应链各成员的最优决策和绩效问题,对比分析了定制和订购两种减排模式下的供应链博弈均衡和供应链成员绩效。研究发现,在碳交易规制下,定制和订购两种减排合作模式下供应链成员均存在最优决策。在定制模式下,单位产品的初始排放量和制造商的减排成本系数提高一定会降低最优产量、单位产品减排量和减排服务价格,减排服务商的减排成本系数提高会降低最优产量和单位产品减排量,但不一定会降低减排服务价格;在订购模式下单位产品初始排放量、制造商和减排服务商的成本系数对企业决策的影响不一定如此。当需求函数满足均匀分布时,无论制造商和减排服务商的减排效率如何,订购模式对减排服务商更有利,定制模式对制造商更有利,但供应链系统总利润的高低与制造商的减排成本系数有关。     

考虑非周期检测的视情维修与备件订购联合策略优化

针对单部件系统/关键部件提出视情维修与备件订购联合策略,其中系统退化服从两阶段延迟时间过程且采用非周期检测策略,退化初期以检测间隔T₁检查系统状态,而在第一次识别缺陷状态时,缩短检测周期为T₂、订购备件且进行不完美维修;若系统在随后的退化中被识别处于缺陷状态,执行不完美维修直至超过阈值次数N_max并采取预防性更换,但若在检测周期内发生故障则进行更换。根据系统状态和备件状态分析各种可能更新事件及相应的联合决策,利用更新报酬理论构建最小化单位时间内期望成本的目标函数,优化T₁,T₂, N_max。与对比模型策略相比,算例结果表明所提出的联合策略能有效降低单位时间内的期望成本。