A general age-replacement model with minimal repair under renewing free-replacement warranty

A general age-replacement model in which incorporates minimal repair, planned and unplanned replacement, is considered in this paper for products under a renewing free-replacement warranty policy. For both warranted and non-warranted products, cost models from the user’s perspective are developed, and the corresponding optimal replacement ages are derived such that the long-run expected cost rate is minimized. The impacts of a product warranty on the optimal replacement model are investigated analytically. Furthermore, we show that the optimal replacement age for a warranted product is closer to the end of the warranty period than for a non-warranted product. Finally, numerical examples are given for illustration.     

Optimal periodic replacement policy for repairable products under free-repair warranty

This paper investigates the effects of a free-repair warranty on the periodic replacement policy for a repairable product. Cost models are developed for both a warranted and a non-warranted product, and the corresponding optimal periodic replacement policies are derived such that the long-run expected cost rate is minimized. For a product with an increasing failure rate function, structural properties of these optimal policies are obtained. By comparing these optimal policies, we show that the optimal replacement period for a warranted product should be adjusted toward the end of the warranty period. Finally, examples are given to numerically illustrate the impact of a product warranty on the optimal periodic replacement policy.     

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.     

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.     

A minimal repair replacement model with two types of failure and a safety constraint

Consider a system subject to two types of failures. If the failure is of type 1, the system is minimally repaired, and a cost C₁ is incurred. If the failure is of type 2, the system is minimally repaired with probability p and replaced with probability 1−p  . The associated costs are _C2,_m$C_{2\text{,}m}$ and _C2,_r$C_{2\text{,}r}$, respectively. Failures of type 2 are safety critical and to control the risk, management has specified a requirement that the probability of at least one such failure occurring in the interval [0, A] should not exceed a fixed probability limit ω. The problem is to determine an optimal planned replacement time T, minimizing the expected discounted costs under the safety constraint. A cost C_r is incurred whenever a planned replacement is performed. Conditions are established for when the safety constraint affects the optimal replacement time and causes increased costs.     

Optimal maintenance strategy for non‐renewing replacement–repair warranty

In this paper, we study the maintenance policy following the expiration of the non‐renewing replacement–repair warranty (NRRW). For such purposes, we first define the non‐renewing free replacement–repair warranty and the non‐renewing pro rata replacement–repair warranty. Then the maintenance model following the expiration of the NRRW is discussed from the user's point of view. As the criterion to determine the optimal maintenance strategy, we formulate the expected cost rate per unit time from the user's perspective. All system maintenance costs incurred after the warranty is expired are paid by the user. Given the cost structures during the life cycle of the system, we determine the optimal maintenance period following the expiration of the NRRW. Finally, a few numerical examples are given for illustrative purposes. Copyright © 2012 John Wiley & Sons, Ltd.     

Inspection scheduling for imperfect production processes under free repair warranty contract

The paper considers scheduling of inspections for imperfect production processes where the process shift time from an ‘in-control’ state to an ‘out-of-control’ state is assumed to follow an arbitrary probability distribution with an increasing failure (hazard) rate and the products are sold with a free repair warranty (FRW) contract. During each production run, the process is monitored through inspections to assess its state. If at any inspection the process is found in ‘out-of-control’ state, then restoration is performed. The model is formulated under two different inspection policies: (i) no action is taken during a production run unless the system is discovered in an ‘out-of-control’ state by inspection and (ii) preventive repair action is undertaken once the ‘in-control’ state of the process is detected by inspection. The expected sum of pre-sale and post-sale costs per unit item is taken as a criterion of optimality. We propose a computational algorithm to determine the optimal inspection policy numerically, as it is quite hard to derive analytically. To ease the computational difficulties, we further employ an approximate method which determines a suboptimal inspection policy. A comparison between the optimal and suboptimal inspection policies is made and the impact of FRW on the optimal inspection policy is investigated in a numerical example.     

An optimization of a continuous time risk process

A continuous time risk process is considered, where the premium rate is constant and the claims form a compound Poisson process. We assume that an action is taken, either an investment to other business when the level of surplus reaches V>0$V>0$ or an injection of capital when the surplus goes below τ(0<τ<V)$\tau (0<\tau <V)$. After assigning several costs related to managing the surplus, we obtain the long-run average cost per unit time. A numerical example is studied.     

Optimal production run length for products sold with warranty

This article studies the optimal production run length for a deteriorating production system in which the products are sold with free minimal repair warranty. The deterioration process of the system is characterized by a two-state continuous-time Markov chain. For products sold with free minimal repair warranty, we show that there exists a unique optimal production run length such that the expected total cost per item is minimized. Since there is no closed form expression for the optimal production run length, an approximate solution is derived. In addition, three special cases which provide bounds for searching the optimal production run length are investigated and some sensitivity analysis is carried out to study the effects of the model parameters on the optimal production run length. Finally, a numerical example is given to evaluate the performance of the optimal production run length.     

有延迟修理的两部件串联系统的预防维修策略

研究由两个部件串联组成的系统的预防维修策略, 当系统的工作时间达到T时进行预防维修, 预防维修使部件恢复到上一次故障维修后的状态. 当部件发生故障后进行故障维修, 因为各种原因可能会延迟修理. 部件在每次故障维修后的工作时间形成随机递减的几何过程, 且每次故障后的维修时间形成随机递增的几何过程. 以部件进行预防维修的间隔T和更换前的故障次数N组成的二维策略(T,N)为策略, 利用更新过程和几何过程理论求出了系统经长期运行单位时间内期望费用的表达式, 并给出了具体例子和数值分析.     

A bivariate mixed policy for a simple repairable system based on preventive repair and failure repair

In this paper, a simple repairable system (i.e. a one-component repairable system with one repairman) with preventive repair and failure repair is studied. Assume that the preventive repair is adopted before the system fails, when the system reliability drops to an undetermined constant R  , the work will be interrupted and the preventive repair is executed at once. And assume that the preventive repair of the system is “as good as new” while the failure repair of the system is not, and the deterioration of the system is stochastic. Under these assumptions, by using geometric process, we present a bivariate mixed policy (R,N)$(R\text{,}N)$, respectively based on a scale of the system reliability and the failure-number of the system. Our aim is to determine an optimal mixed policy (R,N)^∗$(R\text{,}N{)}^{\ast }$ such that the long-run average cost per unit time (i.e. the average cost rate) is minimized. The explicit expression of the average cost rate is derived, and the corresponding optimal mixed policy can be determined analytically or numerically. Finally, a numerical example is given where the working time of the system yields a Weibull distribution. Some comparisons with a certain existing policy are also discussed by numerical methods.     

Repairable failure-delay systems with elementary structure

This paper defines repairable failure-delay systems, and gives explicit formulae for their availability. It presents models for single-component, series and parallel systems with delay at system level, and a ‘rare event’ approximation for availability and reliability of series systems with delay at component level. Finally, it uses a renewal terminating process for deriving the limiting distribution of the lifetime of failure-delay systems.     

A bivariate optimal replacement policy for a cold standby repairable system with preventive repair

In this paper, the repair-replacement problem for a deteriorating cold standby repairable system is investigated. The system consists of two dissimilar components, in which component 1 is the main component with use priority and component 2 is a supplementary component. In order to extend the working time and economize the running cost of the system, preventive repair for component 1 is performed every time interval T, and the preventive repair is “as good as new”. As a supplementary component, component 2 is only used at the time that component 1 is under preventive repair or failure repair. Assumed that the failure repair of component 1 follows geometric process repair while the repair of component 2 is “as good as new”. A bivariate repair-replacement policy (T, N) is adopted for the system, where T is the interval length between preventive repairs, and N is the number of failures of component 1. The aim is to determine an optimal bivariate policy (T, N)^∗ such that the average cost rate of the system is minimized. The explicit expression of the average cost rate is derived and the corresponding optimal bivariate policy can be determined analytically or numerically. Finally, a Gamma distributed example is given to illustrate the theoretical results for the proposed model.     

Optimal overhaul intervals with imperfect inspection and repair

Author for correspondence.Email:m.j.newby{at}city.ac.uk This paper is motivated by the idea of a maintenance-free operatingperiod whose objectives are to improve mission reliability andcarry out as much maintenance as possible as a second-line activity.The system may be in one of three states (good, faulty, andfailed), and expressions are developed for the average costper unit time until failure. The system is periodically inspected,the inspection being imperfect in the sense that it can resultin both false-positive and false-negative results. Simple faultscan be fixed, but a repair is imperfect, in that there is anon-zero probability of a fault remaining after a repair. Aftera fixed number of inspections, the system is overhauled. Ifthe system fails during operation, it is replaced at increasedcost. The sojourn time in each state has non-constant failurerate, and discretization and supplementary variables are usedto give a Markovian structure which allows easy computationof the average costs. Minimizing the average cost gives theoptimal number of inspections before overhauling the 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^∗).     

Determination/estimation of an optimal replacement interval under minimal repair

In this paper the problem of estimation of an optimal replacement interval for a system which is minimally repaired at failures is studied. The problem is investigated both under a parametric and a nonparametric form of the failure intensity of the system. It is assumed that observational data from n systems are available. Some asymptotic results are shown. A graphical procedure for determining/estimating an optimal replacement interval is presented. The procedure is particularly valuable for sensitivity analyses, for example with respect to the costs involved.     

A partial replenishment model for an inventory with constant demand

An inventory with constant demand is considered. The inventory is checked according to a Poisson process and replenished either fully or partially when the stock is below a threshold. We obtained the stationary distribution of the level of the inventory. After assigning several costs to the inventory, we also derived the long-run average cost per unit time. A numerical example is studied to find the optimal values of the checking rate and threshold, which minimize the long-run average cost.     

Optimal burn-in for maximizing reliability of repairable non-series systems

Burn-in is a manufacturing process applied to products to eliminate early failures in the factory before the products reach the customers. Various methods have been proposed for determining an optimal burn-in time of a non-repairable system or a repairable series system, assuming that system burn-in improves all components in the system. In this paper, we establish the trade-off between the component reliabilities during system burn-in and develop an optimal burn-in time for repairable non-series systems to maximize reliability. One impediment to expressing the reliability of a non-series system is in that successive failures during system burn-in cannot be described precisely because a failed component is not detected until the whole system fails. For approximating the successive failures of a non-series system during system burn-in, we considered two types of repair: minimal repair at the time of system failure, and repair at the time of component or connection failure. The two types of repair provide bounds on the optimal system burn-in time of non-series systems.     

Optimizing replacement policy for a cold-standby system with waiting repair times

This paper presents the formulas of the expected long-run cost per unit time for a cold-standby system composed of two identical components with perfect switching. When a component fails, a repairman will be called in to bring the component back to a certain working state. The time to repair is composed of two different time periods: waiting time and real repair time. The waiting time starts from the failure of a component to the start of repair, and the real repair time is the time between the start to repair and the completion of the repair. We also assume that the time to repair can either include only real repair time with a probability p, or include both waiting and real repair times with a probability 1 − p. Special cases are discussed when both working times and real repair times are assumed to be geometric processes, and the waiting time is assumed to be a renewal process. The expected long-run cost per unit time is derived and a numerical example is given to demonstrate the usefulness of the derived expression.     

有两种故障状态的两部件串联系统的预防维修策略

本文研究的是由两个部件串联组成且有两种故障状态的系统的预防维修策略, 当系统的工作时间达到T时进行预防维修, 预防维修使部件恢复到上一次故障维修后的状态。每个部件发生故障都有两种状态, 可维修和不可维修。当部件的故障为可维修故障时, 修理工对其进行故障维修, 且每次故障维修后的工作时间形成随机递减的几何过程, 每次故障后的维修时间形成随机递增的几何过程。当部件发生N次可维修故障或一次不可维修故障时进行更换。以部件进行预防维修的间隔和更换前的可维修故障次数N组成的二维策略(T, N) 为策略, 利用更新过程和几何过程理论求出了系统经长期运行单位时间内期望费用的表达式, 并给出了具体例子和数值分析。