Comparison of maintenance policies with monotone failure rate distributions

We compare different maintenance policies assuming that the system lifetime has either increasing failure rate (IFR), or decreasing failure rate (DFR) distribution. We show that these assumptions yield strongly stochastic comparisons between the process' intensities. This yields weaker stochastic comparison between the processes than the stochastic comparison that hold when the system lifetime is new better than used (NBU) or new worse than used (NWU). Copyright © 2002 John Wiley & Sons, Ltd.     

Marginal cost analysis of single-item maintenance policies with several decision variables

The marginal cost approach for the analysis of repair/replacementmodels was introduced by Berg in 1980 and has since been appliedto many maintenance policies of various complexity. All modelshitherto analysed in the literature by the marginal cost approachhave one single decision variable only, this being, typically,the age of the current item at the time of ordering or replacement.This paper is concerned with the extension of the marginal costtechnique to maintenance policies with several decision variables.After addressing the general framework appropriate for the multi-parametercase, we exemplify the workings of the technique by analysinga two-variable maintenance model involving replacement and minimalrepair. We demonstrate that the marginal cost approach is anattractive and intuitively appealing technique also for modelswith several decision variables. Just as in the single-parametersituation, the approach is amenable to economic interpretation,a welcome feature for users of maintenance models with a primeinterest in its economic (rather than its mathematical) aspects.As an added bonus of the marginal cost approach, in our example,some otherwise necessary tools from the theory of stochasticprocesses are dispensable.     

A maintenance model with failures and inspection following Markovian arrival processes and two repair modes

We consider a deteriorating system submitted to external and internal failures, whose deterioration level is known by means of inspections. There are two types of repairs: minimal and perfect, depending on the deterioration level, each one following a different phase-type distribution. The failures and the inspections follow different Markovian arrival processes (MAP). Under these assumptions, the system is governed by a generalized Markov process, whose state space and generator are constructed. This general model includes the phase-type renewal process as a special case. The distribution of the number of minimal and perfect repairs between two inspections are determined. A numerical application optimizing costs is performed, and different particular cases of the model are compared.     

Time and inventory dependent optimal maintenance policies for single machine workstations: An MDP approach

In this work the problem of obtaining an optimal maintenance policy for a single-machine, single-product workstation that deteriorates over time is addressed, using Markov Decision Process (MDP) models. Two models are proposed. The decision criteria for the first model is based on the cost of performing maintenance, the cost of repairing a failed machine and the cost of holding inventory while the machine is not available for production. For the second model the cost of holding inventory is replaced by the cost of not satisfying the demand. The processing time of jobs, inter-arrival times of jobs or units of demand, and the failure times are assumed to be random. The results show that in order to make better maintenance decisions the interaction between the inventory (whether in process or final), and the number of shifts that the machine has been working without restoration, has to be taken into account. If this interaction is considered, the long-run operational costs are reduced significantly. Moreover, structural properties of the optimal policies of the models are obtained after imposing conditions on the parameters of the models and on the distribution of the lifetime of a recently restored machine.     

The impact of process deterioration on production and maintenance policies

This paper examines a single-stage production system that deteriorates with production actions, and improves with maintenance. The condition of the process can be in any of several discrete states, and transitions from state to state follow a semi-Markov process. The firm can produce multiple products, which differ by profit earned, expected processing time, and impact on equipment deterioration. The firm can also perform different maintenance actions, which differ by cost incurred, expected down time, and impact on the process condition. The firm needs to determine the optimal production and maintenance choices in each state in a way that maximizes the long-run expected average reward per unit time.     

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.     

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.     

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 maintenance service contract negotiation with aging equipment

In recent years, there has been a growing trend to out-source service operations in which the equipment maintenance is carried out by an external agent rather than in-house. Often, the agent (service provider) offers more than one option and the owners of equipment (customers) are faced to the problem of selecting the optimal option, under the terms of a contract. In the current work, we develop a model and report results to determine the agent’s optimal strategy for a given type of contract. The model derives in a non-cooperative game formulation in which the decisions are taken by maximizing expected profits. This work extends previous models by considering the realistic case of equipments having an increasing failure intensity due to imperfect maintenance, instead of the standard assumption that considers failure times are exponentially distributed (constant failure intensity). We develop a model using a linear function of time to characterize the failure intensity. The main goal, for the agent, is to determine the pricing structure in the contract and the number of customers to service. On the other hand, for the clients, the main goal is to define the period between planned actions for preventive maintenance and the time to replace equipments. In order to give a complete characterization of the results, we also carry out a sensitivity analysis over some of the factors that would influence over the failure intensity.     

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^∗).     

Hybrid block replacement and inspection policies for a multi-component system with heterogeneous component lives

Novel replacement policies that are hybrids of inspection maintenance and block replacement are developed for an n identical component series system in which the component parts used at successive replacements arise from a heterogeneous population. The heterogeneous nature of components implies a mixed distribution for time to failure. In these circumstances, a hybrid policy comprising two phases, an early inspection phase and a later wear-out replacement phase, may be appropriate. The policy has some similarity to burn-in maintenance. The simplest policy described is such a hybrid and comprises a block-type or periodic replacement policy with an embedded block or periodic inspection policy. We use a three state failure model, in which a component may be good, defective or failed, in order to consider inspection maintenance. Hybrid block replacement and age-based inspection, and opportunistic hybrid policies will also arise naturally in these circumstances and these are briefly investigated. For the simplest policy, an approximation is used to determine the long-run cost and the system reliability. The policies have the interesting property that the system reliability may be a maximum when the long-run cost is close to its minimum. The failure model implies that the effect of maintenance is heterogeneous. The policies themselves imply that maintenance is carried out more prudently to newer than to older systems. The maintenance of traction motor bearings on underground trains is used to illustrate the ideas in the paper.     

A comparison of inventory policies for perishable goods

Past research on inventory management of perishables introduced models in which demand is sensitive to the age of the product. For such models, we prove that a fixed-order quantity policy is optimal under certain conditions and show that its expected cost is closer to optimal than that of the base-stock level policy when there is demand for units of all ages. We also show numerically when substituting older products to fulfill the demand for new (or vice versa) is beneficial.     

Basic optimality results for Bayesian group replacement policies

The optimal structure of Bayesian group replacement policies for a parallel system of n items with exponential failure times and random failure parameter is presented. The paper contains a proof of the fact that it is optimal to observe the system only at failure times. For the case of two items operating in parallel the exact form of the policy is derived.     

Information security trade-offs and optimal patching policies

We develop and simulate a basic mathematical model of the costly deployment of software patches in the presence of trade-offs between confidentiality and availability. The model incorporates representations of the key aspects of the system architecture, the managers’ preferences, and the stochastic nature of the threat environment. Using the model, we compute the optimal frequencies for regular and irregular patching, for both networks and clients, for two example types of organization, military and financial. Such examples are characterized by their constellations of parameters. Military organizations, being relatively less cost-sensitive, tend to apply network patches upon their arrival. The relatively high cost of applying irregular client patches leads both types of organization to avoid deployment upon arrival.     

Some results on semilinear stochastic differential equations in hilbert spaces

We study a semilinear stochastic equation by reducing it to a deterministic problem     

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.     

Extended optimal inspection policies for a system in storage

A system such as missiles and spare parts of aircraft has to perform a normal operation in a severe environment at any time when it is used. However, the system is in storage for a long time from the delivery to the usage and its reliability goes down with time. Thus, a system in storage should be inspected and maintained at periodic times to hold a higher reliability than is prespecified.The following inspection model is considered: A system has three types of units, where unit 1 is maintained, unit 21 is not maintained but is replaced and unit 22 is neither maintained nor replaced. The system is overhauled if its reliability becomes lower than a prespecified probability. The number of replacements and time until overhaul are derived. Using these results, the average cost is obtained and both an optimal inspection time and an optimal replacement time to minimize it are numerically discussed.     

Optimal warranty policies for systems with imperfect repair

We investigate a system whose basic warranty coverage is minimal repair up to a specified warranty length. An additional service is offered whereby first failure is restored up to the consumers’ chosen level of repair. The problem is studied under two system replacement strategies: periodic maintenance before and after warranty. It turns out that our model generalizes the model of Rinsaka and Sandoh [K. Rinsaka, H. Sandoh, A stochastic model with an additional warranty contract, Computers and Mathematics with Applications 51 (2006) 179–188] and the model of Yeh et al. [R.H. Yeh, M.Y. Chen, C.Y. Lin, Optimal periodic replacement policy for repairable products under free-repair warranty, European Journal of Operational Research 176 (2007) 1678–1686]. We derive the optimal maintenance period and optimal level of repair based on the structures of the cost function and failure rate function. We show that under certain assumptions, the optimal repair level for additional service is an increasing function of the replacement time. We provide numerical studies to verify some of our results.     

Asymptotically optimal production policies in dynamic stochastic jobshops with limited buffers

We consider a production planning problem for a jobshop with unreliable machines producing a number of products. There are upper and lower bounds on intermediate parts and an upper bound on finished parts. The machine capacities are modelled as finite state Markov chains. The objective is to choose the rate of production so as to minimize the total discounted cost of inventory and production. Finding an optimal control policy for this problem is difficult. Instead, we derive an asymptotic approximation by letting the rates of change of the machine states approach infinity. The asymptotic analysis leads to a limiting problem in which the stochastic machine capacities are replaced by their equilibrium mean capacities. The value function for the original problem is shown to converge to the value function of the limiting problem. The convergence rate of the value function together with the error estimate for the constructed asymptotic optimal production policies are established.     

Some results on the proportional reversed hazards model

The proportional reversed hazards model consists in describing random failure times by a family {[F(x)]^θ, θ>0} of distribution functions, where F(x) is a baseline distribution function. We show various results on this model related to some topics in reliability theory, including ageing notions of random lifetimes, comparisons based on stochastic orders, and relative ageing of distributions.