A combinatorial approach to level of repair analysis

This paper presents an approach to optimise level of repair decisions taking into account submodular properties of standard life cycle cost functions, which include fixed and variable costs. It proposes an integer programming formulation to solve level of repair problems for multi-echelon multi-indenture level systems. The method converges quickly to the optimum solution relying on heuristics to obtain tight bounds for a subsequent branch-and-bound procedure. A software package called level of repair optimisation model (LOROM) was developed to implement the branch-and-bound method that does not rely on linear programming relaxations. This approach is rather generic and can be applied to a wide class of problems with convex total cost functions such as plant location problems or transportation problems with fixed costs.     

Coordinated condition-based repair strategies for components of a multi-component maintenance system with discounts

This paper presents a heuristic algorithm for computing upper and lower control limit values for the repair of components (which need not be identical) in a multi-component system. The cost structure is composed of repair, operating and failure costs. An essential feature of the model is that reduction in repair costs can be achieved by coordinating the repair of several components and thus paying set-up costs only once. The algorithm searches for a simple rule per component in order to minimise long-run average cost per unit of time for the system as a whole. This opportunistic rule per component has a simple structure: it consists of an upper limit inducing mandatory repair and of several lower limits. Each lower limit corresponds to the potential for saving an amount of repair costs when an opportunity for a specific coordination presents itself. The heuristic procedure is based on decomposition producing single-component problems. Each single-component problem is solved as a Markov decision problem, allowing the model to cope with a large number of components.     

The role of repair strategy in warranty cost minimization: An investigation via quasi-renewal processes

Most companies seek efficient rectification strategies to keep their warranty related costs under control. This study develops and investigates different repair strategies for one- and two-dimensional warranties with the objective of minimizing manufacturer’s expected warranty cost. Static, improved and dynamic repair strategies are proposed and analyzed under different warranty structures. Numerical experimentation with representative cost functions indicates that performance of the policies depend on various factors such as product reliability, structure of the cost function and type of the warranty contract.     

Practical extensions to a minimum cost flow model for level of repair analysis

The level of repair analysis (LORA) gives answers to three questions that are posed when deciding on how to maintain capital goods: (1) which components to repair upon failure and which to discard, (2) at which locations in the repair network to perform each type of repairs, and (3) at which locations in the network to deploy resources, such as test equipment. The goal is to achieve the lowest possible life cycle costs. Various models exist for the LORA problem. However, they tend to be restrictive in that specific business situations cannot be incorporated, such as having repair equipment with finite capacity or the occurrence of unsuccessful repairs or no-fault-founds. We discuss and model such practically relevant extensions to an existing minimum cost flow formulation for the LORA problem. In an extensive numerical experiment, we show that incorporating the model refinements leads to a substantial change in the costs in general. The repair strategy changes substantially only when incorporating finite resource capacities or a probability of unsuccessful repair that is decreasing with an increasing echelon level.     

On sourcing and stocking policies in a two-echelon,multiple location,repairable parts supply chain

This research develops policies to minimize spare part purchases and repair costs for maintaining a fleet of mission-critical systems that operate from multiple forward (base) locations within a two-echelon repairable supply chain with a central depot. We take a tactical planning perspective to support periodic decisions for spare part purchases and repair sourcing, where the repair capabilities of the various locations are overlapping. We consider three policy classes: a central policy, where all repairs are sourced to a central depot; a local policy, whereby failures are repaired at forward locations; and a mixed policy, where a fraction of the parts is repaired at the bases and the remainder is repaired at the depot. Parts are classified based on their repair cost and lead time. For each part class, we suggest a solution that is based on threshold policies or on the use of a heuristic solution algorithm that extends the industry standard of marginal analysis to determine spare parts positioning by including repair fraction sourcing. A validation study shows that the suggested heuristic performs well compared to an exhaustive search (an average 0.2% difference in cost). An extensive numerical study demonstrates that the algorithm achieves costs which are lower by about 7–12% on average, compared to common, rule-based sourcing policies.     

Joint optimization of level of repair analysis and spare parts stocks

In the field of after sales service logistics for capital goods, generally, METRIC type methods are used to decide where to stock spare parts in a multi-echelon repair network such that a target availability of the capital goods is achieved. These methods generate a trade-off curve of spares investment costs versus backorders. Backorders of spare parts lead to unavailability of the capital goods. Inputs in the spare parts stocking problem are decisions on (1) which components to repair upon failure and which to discard, and (2) at which locations in the repair network to perform the repairs and discards. The level of repair analysis (LORA) can be used to make such decisions in conjunction with the decisions (3) at which locations to deploy resources, such as test equipment that are required to repair, discard, or move components. Since these decisions significantly impact the spare parts investment costs, we propose to solve the LORA and spare parts stocking problems jointly. We design an algorithm that finds efficient solutions. In order for the algorithm to be exact and because of its computational complexity, we restrict ourselves to two-echelon, single-indenture problems. In a computational experiment, we show that solving the joint problem is worthwhile, since we achieve a cost reduction of over 43% at maximum (5.1% on average) compared with using a sequential approach of first solving a LORA and then the spare parts stocking problem.     

Optimal corrective maintenance contract planning for aging multi‐state system

This paper considers an aging multi‐state system, where the system failure rate varies with time. After any failure, maintenance is performed by an external repair team. Repair rate and cost of each repair are determined by a corresponding corrective maintenance contract with a repair team. The service market can provide different kinds of maintenance contracts to the system owner, which also can be changed after each specified time period. The owner of the system would like to determine a series of repair contracts during the system life cycle in order to minimize the total expected cost while satisfying the system availability. Operating cost, repair cost and penalty cost for system failures should be taken into account. The paper proposes a method for determining such optimal series of maintenance contracts. The method is based on the piecewise constant approximation for an increasing failure rate function in order to assess lower and upper bounds of the total expected cost and system availability by using Markov models. The genetic algorithm is used as the optimization technique. Numerical example is presented to illustrate the approach. Copyright © 2009 John Wiley & Sons, Ltd.     

Optimal impulse control on an unbounded domain with nonlinear cost functions

In this paper we consider the optimal impulse control of a system which evolves randomly in accordance with a homogeneous diffusion process in ℜ¹. Whenever the system is controlled a cost is incurred which has a fixed component and a component which increases with the magnitude of the control applied. In addition to these controlling costs there are holding or carrying costs which are a positive function of the state of the system. Our objective is to minimize the expected discounted value of all costs over an infinite planning horizon. Under general assumptions on the cost functions we show that the value function is a weak solution of a quasi-variational inequality and we deduce from this solution the existence of an optimal impulse policy. The computation of the value function is performed by means of the Finite Element Method on suitable truncated domains, whose convergence is discussed. Mathematics Subject Classification: 49J40, 60G40, 65N30     

Optimal control of a divergent multi-echelon inventory system

Consider a divergent multi-echelon inventory system, such as a distribution system or a production system. At every facility in the system orders are placed (or production is initiated) periodically. The order arrives after a fixed lead time. At the end of each period linear costs are incurred penalty costs are incurred at the most downstream facilities for back-orders. The objective is to minimize the expected holding and penalty costs per period. We prove that under the balance assumption it is cost optimal to control every facility by an order-up-to-policy. The optimal replenishment policy, i.e. the order-up-to-level and the allocation functions at each facility, can be determined by system decomposition. This decomposition reduces complex multi-dimensional control problems to simple one-dimensional problems.     

Facility location with increasing production costs

Facility location models determine the set of locations on a network that minimize the sum of the costs of investment, production, and distribution to meet a known set of demands. In this paper, we introduce a new type of facility location model, which combines aspects of the well-studied simple uncapacitated and capacitated facility location problems. Its distinctive feature is that unit production costs are modeled as increasing with scale of output. Such cost functions have practical value in handling cases in which capacity can be “stretched” by incurring some additional cost (e.g., by adding workers). Indeed, it is shown that average total costs are minimized at a point where average production costs are rising. Four different formulations for this problem are proposed. Using linear programming plus branch-and-bound as a solution method, the four formulations are tested and compared on a set of 216 problems with randomly generated data.     

Scheduling policies for a repair shop problem

In this paper, we analyze a repair shop serving several fleets of machines that fail from time to time. To reduce downtime costs, a continuous-review spare machine inventory is kept for each fleet. A spare machine, if available on stock, is installed instantaneously in place of a broken machine. When a repaired machine is returned from the repair shop, it is placed in inventory for future use if the fleet has the required number of machines operating. Since the repair shop is shared by different fleets, choosing which type of broken machine to repair is crucial to minimize downtime and holding costs. The optimal policy of this problem is difficult to characterize, and, therefore, is only formulated as a Markov Decision Process to numerically compute the optimal cost and base-stock level for each spare machine inventory. As an alternative, we propose the dynamic Myopic(R) policy, which is easy to implement, yielding costs very close to the optimal. Most of the time it outperforms the static first-come-first-served, and preemptive-resume priority policies. Additionally, via our numerical study, we demonstrate that repair shop pooling is better than reserving a repair shop for each fleet.     

The management of intrusion detection: Configuration,inspection, and investment

This paper analyzes intrusion detection decisions in the presence of multiple alarm types, which differ in occurrence probabilities, damage and investigation costs. Specifically, multi-period optimization models are used to study three critical decisions associated with intrusion detection: (i) Allocation of the investigation budget to different periods and to different alarm types; (ii) Configuration of an intrusion detection system (IDS), i.e. choosing a false alarm rate for a given IDS; and (iii) Allocation of an appropriate amount of the investigation budget in the presence of alternative investment opportunities. Three models that cascade onto each other are presented. We minimize the sum of security costs including damages, due to ignored alarms, the investigation cost and the undetected intrusion cost. We show that it can be optimal to ignore non-critical alarms in order to allocate more of the investigation budget to critical alarms that may occur in the future. We establish that the security costs decrease as the investigation budget increases. Our last model deals with security investments—in the form of an investigation budget. The investigation budget must be increased until the rate of increase in savings in security costs due to the additional budget are equal to the internal rate of return of an organization. These analyses are done with explicit (derived) cost functions, as opposed to implicit (assumed) cost functions. We conclude by providing additional managerial insights and numerical examples.     

基于成本优先级的部件维修策略分析

现实中,系统由于任务、环境等因素,无法实时对故障部件进行维修。因此需要在任务间隔期间或对故障部件进行维修的同时对系统各部件进行预防性机会维修。本文考虑系统期望维修成本,提出了基于部件维修优先级的预防性维修策略。首先把系统期望维修成本分为失效部件维修成本、失效部件导致系统故障的成本和预防性维修其他部件的成本,提出了基于成本的二态和多态系统部件维修优先级度量方法,并在两种场景下分析了如何选择预防性维修部件。其次针对多态系统,研究了基于成本重要度的部件最佳维修水平,并讨论了成本约束下的部件预防性维修策略。最后以某型预警机系统为例进行验证,结果表明,基于成本的预防性维修策略不仅与故障部件位置和相关成本有关,而且还与可用于预防性维修的其他部件重要性有关。     

Cooperation in assembly systems: The role of knowledge sharing networks

Process improvement plays a significant role in reducing production costs over the life cycle of a product. We consider the role of process improvement in a decentralized assembly system in which a buyer purchases components from several first-tier suppliers. These components are assembled into a finished product, which is sold to the downstream market. The assembler faces a deterministic demand/production rate and the suppliers incur variable inventory costs and fixed setup production costs. In the first stage of the game, which is modeled as a non-cooperative game among suppliers, suppliers make investments in process improvement activities to reduce the fixed production costs. Upon establishing a relationship with the suppliers, the assembler establishes a knowledge sharing network – this network is implemented as a series of meetings among suppliers and also mutual visits to their factories. These meetings facilitate the exchange of best practices among suppliers with the expectation that suppliers will achieve reductions in their production costs from the experiences learned through knowledge sharing. We model this knowledge exchange as a cooperative game among suppliers in which, as a result of cooperation, all suppliers achieve reductions in their fixed costs. In the non-cooperative game, the suppliers anticipate the cost allocation that results from the cooperative game in the second stage by incorporating the effect of knowledge sharing in their cost functions. Based on this model, we investigate the benefits and challenges associated with establishing a knowledge sharing network. We identify and compare various cost allocation mechanisms that are feasible in the cooperative game and show that the system optimal investment levels can be achieved only when the most efficient supplier receives the incremental benefits of the cost reduction achieved by other suppliers due to the knowledge transfer.     

Level of repair analysis and minimum cost homomorphisms of graphs

Level of repair analysis (LORA) is a prescribed procedure for defense logistics support planning. For a complex engineering system containing perhaps thousands of assemblies, sub-assemblies, components, etc. organized into several levels of indenture and with a number of possible repair decisions, LORA seeks to determine an optimal provision of repair and maintenance facilities to minimize overall life-cycle costs. For a LORA problem with two levels of indenture with three possible repair decisions, which is of interest in UK and US military and which we call LORA-BR, Barros [The optimisation of repair decisions using life-cycle cost parameters. IMA J. Management Math. 9 (1998) 403-413] and Barros and Riley [A combinatorial approach to level of repair analysis, European J. Oper. Res. 129 (2001) 242-251] developed certain branch-and-bound heuristics. The surprising result of this paper is that LORA-BR is, in fact, polynomial-time solvable. To obtain this result, we formulate the general LORA problem as an optimization homomorphism problem on bipartite graphs, and reduce a generalization of LORA-BR, LORA-M, to the maximum weight independent set problem on a bipartite graph. We prove that the general LORA problem is NP-hard by using an important result on list homomorphisms of graphs. We introduce the minimum cost graph homomorphism problem, provide partial results and pose an open problem. Finally, we show that our result for LORA-BR can be applied to prove that an extension of the maximum weight independent set problem on bipartite graphs is polynomial time solvable.     

Optimising a general repair kit problem with a service constraint

Field services are a particular type of after-sales service performed at the customer’s location where technicians repair malfunctioning machines. The inventory decisions about which spare part types to take to the repair site and in what quantities is called the repair kit problem. This problem is characterized by an order-based performance measure since a customer is only satisfied when all required spare parts are available to fix the machine. As a result, the service level in the decision making process is defined as a job fill rate. In this paper we derive a closed-form expression for the expected service level and total costs for the repair kit problem in a general setting, where multiple units of each part type can be used in a multi-period problem. Such an all-or-nothing strategy is a new characteristic to investigate, but commonly used in practice. Namely, items are only taken from the inventory when all items to perform the repair are available in the right quantity. We develop a new algorithm to determine the contents of the repair kit both for a service and cost model while incorporating this new expression for the job fill rate. We show that the algorithm finds solutions which differ on average 0.2% from optimal costs. We perform a case study to test the performance of the algorithm in practice. Our approach results in service level improvements of more than 30% against similar holding costs.     

Efficient neighborhood search for the one-machine earliness–tardiness scheduling problem

This paper addresses the one-machine scheduling problem where the objective is to minimize a sum of costs such as earliness–tardiness costs. Since the sequencing problem is NP-hard, local search is very useful for finding good solutions. Unlike scheduling problems with regular cost functions, the scheduling (or timing) problem is not trivial when the sequence is fixed. Therefore, the local search approaches must deal with both job interchanges in the sequence and the timing of the sequenced jobs. We present a new approach that efficiently searches in a large neighborhood and always returns a solution for which the timing is optimal.     

Single facility location and relocation problem with time dependent weights and discrete planning horizon

In this paper a single facility location problem with multiple relocation opportunities is investigated. The weight associated with each demand point is a known function of time. We consider either rectilinear, or squared Euclidean, or Euclidean distances. Relocations can take place at pre-determined times. The objective function is to minimize the total location and relocation costs. An algorithm which finds the optimal locations, relocation times and the total cost, for all three types of distance measurements and various weight functions, is developed. Locations are found using constant weights, and relocations times are the solution to a Dynamic Programming or Binary Integer Programming (BIP) model. The time horizon can be finite or infinite.     

Optimal expansion of capacitated transshipment networks

In this paper, we address the problem of allocating a given budget to increase the capacities of arcs in a transshipment network to minimize the cost of flow in the network. The capacity expansion costs of arcs are assumed to be piecewise linear convex functions. We use properties of the optimum solution to convert this problem into a parametric network flow problem. The concept of optimum basis structure is used which allows us to consider piecewise linear convex functions without introducing additional arcs. The resulting algorithm yields an optimum solution of the capacity expansion problem for all budget levels less than or equal to the given budget. For integer data, the algorithm performs almost all computations in integers. Detailed computational results are also presented.     

Optimally maintaining a Markovian deteriorating system with limited imperfect repairs

We consider the problem of optimally maintaining a periodically inspected system that deteriorates according to a discrete-time Markov process and has a limit on the number of repairs that can be performed before it must be replaced. After each inspection, a decision maker must decide whether to repair the system, replace it with a new one, or leave it operating until the next inspection, where each repair makes the system more susceptible to future deterioration. If the system is found to be failed at an inspection, then it must be either repaired or replaced with a new one at an additional penalty cost. The objective is to minimize the total expected discounted cost due to operation, inspection, maintenance, replacement and failure. We formulate an infinite-horizon Markov decision process model and derive key structural properties of the resulting optimal cost function that are sufficient to establish the existence of an optimal threshold-type policy with respect to the system’s deterioration level and cumulative number of repairs. We also explore the sensitivity of the optimal policy to inspection, repair and replacement costs. Numerical examples are presented to illustrate the structure and the sensitivity of the optimal policy.