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.     

Optimal spare ordering policy under a rebate warranty

This paper develops, from the customer’s perspective, the optimal spare ordering policy for a non-repairable product with a limited-duration lifetime and under a rebate warranty. The spare unit for replacement is available only by order and the lead time for delivery follows a specified probability distribution. Through evaluation of gains due to the rebate and the costs due to ordering, shortage, and holding, we derive the expected cost per unit time and cost effectiveness in the long run and examine the optimal ordering time by minimizing or maximizing these cost expressions. We show that there exists a unique optimum solution under mild assumptions. We provide a numerical example and illustrate sensitivity analysis.     

Generalized spare ordering policies with random lead time

Generalized ordering policies for a spare unit with general life time and lead time distributions are considered. Introducing the costs of ordering, shortage, and holding, we derive the expected cost rate and the cost effectiveness. We show that the generalized ordering policy minimizing the cost rate or maximizing the cost effectiveness is either one of the two typical ordering policies: (1) the original unit is replaced as soon as the ordered spare is delivered, or (2) the delivered spare is put into inventory until the original unit fails. Some properties regarding the optimum ordering policy and the optimum ordering time are also presented.     

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.     

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     

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。     

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。     

A condition-based order-replacement policy for a single-unit system

This paper presents a condition-based order-replacement policy for a single-unit system, aiming to optimize the condition-based maintenance and the spare order management jointly. The concerned system deteriorates stochastically and gradually, and is inspected periodically. Under the proposed policy, both the preventive replacement and the spare order are decided based on the observed deterioration level of the system. Therefore, the decision variables for this order-replacement problem include the inspection interval, the ordering threshold, and the preventive replacement threshold. The analytical modeling of the condition-based order-replacement policy is presented in detail in this paper. The policy performance is evaluated in terms of the long-run average cost per unit time, the mean availability, and the rate of preventive replacement, for which the mathematical models are also derived. Numerical examples illustrate the performance of the condition-based order-replacement policy, especially the influences of the lead time of the spare order over the different performance criteria.     

Analysis of the asset replacement level with an uncertain salvage value: a two-factor model

The aim of this article is to analyse the asset replacement problem from the perspective of optimal replacement level, given a specific tax environment and depreciation policy. Using a real options approach, our model minimizes current operation and maintenance costs and allows the definition of a new value of the replacement flexibility within a multi-cycle environment. The innovation on the valuation process comes from adding an autonomous salvage value’s factor. The results from partial differential equations reveal relevant differences from those observed in one-factor models, especially with regard to optimal replacement levels and in the non-monotonous effects of salvage value variation. The numerical case study also confirms that the salvage value is indeed a worthwhile element in the replacement process. It was possible to determine that, in terms of the magnitude of the cost replacement level, the key roles are played by changes in the speed of mean reversion, as well in the salvage factor volatility. This paper provides some improvements to the existing literature in equivalent annual cost by drawing up a cost minimization problem conditioned by a different salvage value dynamics, and contributes to real options literature by introducing a salvage value factor in the pricing model.     

Failure replacement and preventive maintenance spare parts ordering policy

This paper addresses inventory policy for spare parts, when demand for the spare parts arises due to regularly scheduled preventive maintenance, as well as random failure of units in service. A stochastic dynamic programming model is used to characterize an ordering policy which addresses both sources of demand in a unified manner. The optimal policy has the form (s(k),S(k)), where k is the number of periods until the next scheduled preventive maintenance operation. The nature of the (s(k),S(k)) policy is characterized through numeric evaluation. The efficiency of the optimal policy is evaluated, relative to a simpler policy which addresses the failure replacement and preventive maintenance demands with separate ordering policies.     

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.     

A multi-objective approach for solving a replacement policy problem for equipment subject to imperfect repairs

This paper proposes a multi-objective approach to model a replacement policy problem applicable to equipment with a predetermined period of use (a planning horizon), which may undergo critical and non-critical failures. Corrective replacements and imperfect repairs are taken to restore the system to operation respectively when critical and non-critical failures occur. Generalized Renewal Process (GRP) is used to model imperfect repairs. The proposed model supports decisions on preventive replacement intervals and the number of spare parts purchased at the beginning of the planning horizon. A Multi-Objective Genetic Algorithm (MOGA) coupled with discrete event simulation (DES) is proposed to provide a set of solutions (Pareto-optimum set) committed to the different objectives of a maintenance manager in the face of a replacement policy problem, that is, maintenance cost, rate of occurrence of failures, unavailability, and investment on spare parts. The proposed MOGA is validated by an application example against the results obtained via the exhaustive approach. Moreover, examples are presented to evaluate the behavior of objective functions on Pareto set (trade-off analysis) and the impact of the repair effectiveness on the decision making.     

智能电表最优更换及备件库存联合决策

智能电表是智能电网运行的关键部件,提高其可靠性和可用度对保证电力的持续不间断供应和准确电能测量至关重要。充足的智能电表库存是其换装与维修的基本保障。本文基于智能电表的故障特性和换装需求分析,建立了智能电表的最优更换与备件库存联合决策模型,并给出了优化方法,以求得可以使系统长期平均运营成本最小的最优更换与备件库存策略。     

Operational asset replacement strategy: A real options approach

This paper analyses the problem of replacement by investigating the optimal moment of investment replacement in a given tax environment with a given depreciation policy. An operation and maintenance cost minimization model, based on the definition of equivalent annual cost, is applied to a real options paradigm. The developed methodology allows for an innovative evaluation of the flexibility of replacement process analysis. A new two-factor evaluation function is introduced to quantify decisions on asset replacement under a unique cycle environment. This study improves upon previous findings in the literature as it accounts for autonomous salvage value processes. Based on partial differential equations, this model achieves a general analytical solution and particular numerical solution. The results differ significantly from those observed in one-factor models by showing evidence of over-evaluation in optimal levels of replacement, and by confirming suspicions that different types of uncertainties produce non-monotonous effects on the optimal replacement level. The scientific contribution of this study lies in new and stronger approaches to equivalent annual cost literature, supplying an algorithm for operation and maintenance cost minimization that is conditioned by autonomous salvage value. This study also contributes to the real options literature by developing a two-factor model with Brownian processes applied to asset replacement.     

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.     

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.     

Optimal order-replacement policy for a phase-type geometric process model with extreme shocks

A system is subject to random shocks that arrive according to a phase-type (PH) renewal process. As soon as an individual shock exceeds some given level the system will break down. The failed system can be repaired immediately. With the increasing number of repairs, the maximum shock level that the system can withstand will be decreasing, while the consecutive repair times after failure will become longer and longer. Undergoing a specified number of repairs, the existing system will be replaced by a new and identical one. The spare system for the replacement is available only by sending a purchase order to a supplier, and the duration of spare system procurement lead time also follows a PH distribution. Based on the number of system failures, a new order-replacement policy (also called $(K\text{,}N)$ policy) is proposed in this paper. Using the closure property of the PH distribution, the long-run average cost rate for the system is given by the renewal reward theorem. Finally, through numerical calculation, it is determined an optimal order-replacement policy such that the long-run expected cost rate is minimum.     

Optimal systems for equipment maintenance and replacement under Markovian deterioration

Deterioration of equipment is modeled as a multistate discrete time controlled Markov process. The states are classified according to the degree of deterioration. The problem of design of optimal systems for equipment maintenance and replacement is considered when the decision-maker may take, in each stage, one of many available maintenance actions, classified according to their “stochastic effectiveness”; no action and replacement are included as alternatives. It is assumed that the transition probabilities satisfy two conditions which effectively describe a trend for monotonically increasing expected deterioration and rate of deterioration. Under these assumptions it is proved in the paper that the optimal (cost minimizing) decision system in an infinite horizon is of the control limit rule type, rapidly obtained by policy improvement algorithms. A numerical example is presented for a specific practical application; detailed data are available from the authors on request.     

Optimal policy for a two-facility inventory problem with storage constraints and two freight modes

This paper considers a two-facility supply chain for a single product in which facility 1 orders the product from facility 2 and facility 2 orders the product from a supplier in each period. The orders placed by each facility are delivered in two possible nonnegative integer numbers of periods. The difference between them is one period. Random demands in each period arise only at facility 1. There are physical storage constraints at both facilities in each period. The objective of the supply chain is to find an ordering policy that minimizes the expected cost over a finite horizon and the discounted stationary expected cost over an infinite horizon. We characterize the structure of the minimum expected cost and the optimal ordering policy for both the finite and the discounted stationary infinite horizon problems.     

具有位相型随机补货提前期的PH退化可修系统及其最优更换策略

将几何过程与PH分布相结合, 讨论一个带有位相型随机补货提前期的PH退化可修系统.通过建立最小生成元$Q$矩阵,获得了系统在稳态情形下的状态概率分布向量及其数值解.根据上述研究结果同时也得到了系统的几个重要可靠性指标. 进一步地,还考虑了基于部件故障次数的订购策略和更换策略,导出系统单位时间平均运行成本的解析表达式并给出一个确定最优$N$策略的数值算例.