Optimal joint preventive maintenance and production policies

We study joint preventive maintenance (PM) and production policies for an unreliable production‐inventory system in which maintenance/repair times are non‐negligible and stochastic. A joint policy decides (a) whether or not to perform PM and (b) if PM is not performed, then how much to produce. We consider a discrete‐time system, formulating the problem as a Markov decision process (MDP) model. The focus of the work is on the structural properties of optimal joint policies, given the system state comprised of the system's age and the inventory level. Although our analysis indicates that the structure of optimal joint policies is very complex in general, we are able to characterize several properties regarding PM and production, including optimal production/maintenance actions under backlogging and high inventory levels, and conditions under which the PM portion of the joint policy has a control‐limit structure. In further special cases, such as when PM set‐up costs are negligible compared to PM times, we are able to establish some additional structural properties. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005.     

Acceptance sampling,imperfect production,and the optimality of zero defects

Acceptance sampling is often used to monitor the quality of raw materials and components when product testing is destructive, time-consuming, or expensive. In this paper we consider the effect of a buyer-imposed acceptance sampling policy on the optimal batch size and optimal quality level delivered by an expected cost minimizing supplier. We define quality as the supplier's process capability, i.e., the probability that a unit conforms to all product specifications, and we assume that unit cost is an increasing function of the quality level. We also assume that the supplier faces a known and constant “pass-through” cost, i.e., a fixed cost per defective unit passed on to the buyer. We show that the acceptance sampling plan has a significant impact on the supplier's optimal quality level, and we derive the conditions under which zero defects (100% conformance) is the policy that minimizes the supplier's expected annual cost. © 1997 John Wiley & Sons, Inc. Naval Research Logistics 44: 515–530, 1997     

Collaboration in contingent capacities with information asymmetry

We study the optimal contracting problem between two firms collaborating on capacity investment with information asymmetry. Without a contract, system efficiency is lost due to the profit‐margin differentials among the firms, demand uncertainty, and information asymmetry. With information asymmetry, we demonstrate that the optimal capacity level is characterized by a newsvendor formula with an upward‐adjusted capacity investment cost, and no first‐best solution can be achieved. Our analysis shows that system efficiency can always be improved by the optimal contract and the improvement in system efficience is due to two factors. While the optimal contract may bring the system's capacity level closer to the first‐best capacity level, it prevents the higher‐margin firm from overinvesting and aligns the capacity‐investment decisions of the two firms. Our analysis of a special case demonstrates that, under some circumstances, both firms can benefit from the principal having better information about the agent's costs. © 2007 Wiley Periodicals, Inc. Naval Research Logistics 54:, 2007     

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

In this article, an optimal replacement policy for a cold standby repairable system consisting of two dissimilar components with repair priority is studied. Assume that both Components 1 and 2, after repair, are not as good as new, and the main component (Component 1) has repair priority. Both the sequence of working times and that of the components'repair times are generated by geometric processes. We consider a bivariate replacement policy (T,N) in which the system is replaced when either cumulative working time of Component 1 reaches T, or the number of failures of Component 1 reaches N, whichever occurs first. The problem is to determine the optimal replacement policy (T,N)* such that the long run average loss per unit time (or simply the average loss rate) of the system is minimized. An explicit expression of this rate is derived, and then optimal policy (T,N)* can be numerically determined through a two‐dimensional‐search procedure. A numerical example is given to illustrate the model's applicability and procedure, and to illustrate some properties of the optimal solution. We also show that if replacements are made solely on the basis of the number of failures N, or solely on the basis of the cumulative working time T, the former class of policies performs better than the latter, albeit only under some mild conditions. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

Optimal maintenance policies for a safety‐critical system and its deteriorating sensor

We consider the integrated problem of optimally maintaining an imperfect, deteriorating sensor and the safety‐critical system it monitors. The sensor's costless observations of the binary state of the system become less informative over time. A costly full inspection may be conducted to perfectly discern the state of the system, after which the system is replaced if it is in the out‐of‐control state. In addition, a full inspection provides the opportunity to replace the sensor. We formulate the problem of adaptively scheduling full inspections and sensor replacements using a partially observable Markov decision process (POMDP) model. The objective is to minimize the total expected discounted costs associated with system operation, full inspection, system replacement, and sensor replacement. We show that the optimal policy has a threshold structure and demonstrate the value of coordinating system and sensor maintenance via numerical examples. © 2017 Wiley Periodicals, Inc. Naval Research Logistics 64: 399–417, 2017     

Return policy: Hassle‐free or your money‐back guarantee?

This article compares the profitability of two pervasively adopted return policies—money‐back guarantee and hassle‐free policies. In our model, a seller sells to consumers with heterogeneous valuations and hassle costs. Products are subject to quality risk, and product misfit can only be observed post‐purchase. While the hassle‐free policy is cost advantageous from the seller's viewpoint, a money‐back guarantee allows the seller to fine‐tune the consumer hassle on returning the product. Thus, when the two return policies lead to the same consumer behaviors, the hassle‐free policy dominates. Conversely, a money‐back guarantee can be more profitable even if on average, high‐valuation consumers experience a lower hassle cost than the low‐valuation ones. The optimal hassle cost can be higher when product quality gets improved; thus, it is not necessarily a perfect proxy or signal of the seller's quality. We further allow the seller to adopt a mixture of these policies, and identify the concrete operating regimes within which these return policies are optimal among more flexible policies. © 2014 Wiley Periodicals, Inc. Naval Research Logistics 61: 403–417, 2014     

On optimal system designs in reliability‐economics frameworks

Reliability Economics is a field that can be defined as the collection of all problems in which there is tension between the performance of systems of interest and their cost. Given such a problem, the aim is to resolve the tension through an optimization process that identifies the system which maximizes some appropriate criterion function (e.g. expected lifetime per unit cost). In this paper, we focus on coherent systems of n independent and identically distributed (iid) components and mixtures thereof, and characterize both a system's performance and cost as functions of the system's signature vector (Samaniego, IEEE Trans Reliabil (1985) 69–72). For a given family of criterion functions, a variety of optimality results are obtained for systems of arbitrary order n. Approximations are developed and justified when the underlying component distribution is unknown. Assuming the availability of an auxiliary sample of N component failure times, the asymptotic theory of L‐estimators is adapted for the purpose of establishing the consistency and asymptotic normality of the proposed estimators of the expected ordered failure times of the n components of the systems under study. These results lead to the identification of ε‐optimal systems relative to the chosen criterion function. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Dynamic inventory management with cash flow constraints

In this article, we consider a classic dynamic inventory control problem of a self‐financing retailer who periodically replenishes its stock from a supplier and sells it to the market. The replenishment decisions of the retailer are constrained by cash flow, which is updated periodically following purchasing and sales in each period. Excess demand in each period is lost when insufficient inventory is in stock. The retailer's objective is to maximize its expected terminal wealth at the end of the planning horizon. We characterize the optimal inventory control policy and present a simple algorithm for computing the optimal policies for each period. Conditions are identified under which the optimal control policies are identical across periods. We also present comparative statics results on the optimal control policy. © 2008 Wiley Periodicals, Inc. Naval Research Logistics 2008     

Optimal redesign decisions through failure rate estimates

To reduce the time-to-market of newly developed systems, manufacturers increasingly adopt strategies where systems are brought to market while system field reliability is still uncertain. These systems are typically sold under performance-based contracts, which incentivizes potential customers to invest in them despite reliability uncertainty. Such contracts make the manufacturer (partly) responsible for the availability of the system. Subsequently, when field reliability is lower than anticipated, the manufacturer may choose to redesign the system to avoid high contract penalties. Redesign is a costly effort which may substantially increase field reliability. Deciding when to redesign is challenging, especially because the initial failure rate estimate by the system's engineers is refined over time as failure data accrues. We propose a model that endogenizes the failure rate updating to analyze this tactical redesign decision. We study additive and multiplicative redesigns and show that the optimal policy has a control limit structure. We benchmark our optimal policy against a static counterpart numerically, and conclude that basing redesign decisions on the updated estimate of the failure rate can substantially reduce costs.     

Supplier certification and quality investment in supply chains

Global sourcing has made quality management a more challenging task, and supplier certification has emerged as a solution to overcome suppliers' informational advantage about their product quality. This article analyzes the impact of certification standards on the supplier's investment in quality, when a buyer outsources the production process. Based on our results, deterministic certification may lead to under‐investment in quality improvement technology for efficient suppliers, thereby leading to potential supply chain inefficiency. The introduction of noisy certification may alleviate this under‐investment problem, when the cost of information asymmetry is high. While allowing noisy certification always empowers the buyer to offer a menu to screen among heterogeneous suppliers, the buyer may optimally choose only a limited number of certification standards. Our analysis provides a clear‐cut prediction of the types of certifiers the buyer should use for heterogeneous suppliers, and we identify the conditions under which the supplier benefits from noisy certification. © 2013 Wiley Periodicals, Inc. Naval Research Logistics, 2013     

批量独立可修件的备件需求预测仿真算法

利用Monte Carlo随机仿真技术,采用事件调度法的仿真策略对可修件的使用与维修过程进行仿真,给出了在给定备件和维修分队数量下批量独立可修件的备件保障概率仿真算法,并用一系列计算实例证明了算法的可行性和正确性,该算法能有效解决安装在不同装备上,具有不同已工作时间、不同故障间隔时间分布、不同修复时间分布的可修件的备件保障概率计算问题,为备件的科学储备提供了有力的决策依据。     

An exact analysis of a joint production‐inventory problem in two‐echelon inventory systems

We consider a two‐echelon inventory system with a manufacturer operating from a warehouse supplying multiple distribution centers (DCs) that satisfy the demand originating from multiple sources. The manufacturer has a finite production capacity and production times are stochastic. Demand from each source follows an independent Poisson process. We assume that the transportation times between the warehouse and DCs may be positive which may require keeping inventory at both the warehouse and DCs. Inventory in both echelons is managed using the base‐stock policy. Each demand source can procure the product from one or more DCs, each incurring a different fulfilment cost. The objective is to determine the optimal base‐stock levels at the warehouse and DCs as well as the assignment of the demand sources to the DCs so that the sum of inventory holding, backlog, and transportation costs is minimized. We obtain a simple equation for finding the optimal base‐stock level at each DC and an upper bound for the optimal base‐stock level at the warehouse. We demonstrate several managerial insights including that the demand from each source is optimally fulfilled entirely from a single distribution center, and as the system's utilization approaches 1, the optimal base‐stock level increases in the transportation time at a rate equal to the demand rate arriving at the DC. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

Optimizing usage and maintenance decisions for k‐out‐of‐n systems of moving assets

We consider an integrated usage and maintenance optimization problem for a k‐out‐of‐n system pertaining to a moving asset. The k‐out‐of‐n systems are commonly utilized in practice to increase availability, where n denotes the total number of parallel and identical units and k the number of units required to be active for a functional system. Moving assets such as aircraft, ships, and submarines are subject to different operating modes. Operating modes can dictate not only the number of system units that are needed to be active, but also where the moving asset physically is, and under which environmental conditions it operates. We use the intrinsic age concept to model the degradation process. The intrinsic age is analogous to an intrinsic clock which ticks on a different pace in different operating modes. In our problem setting, the number of active units, degradation rates of active and standby units, maintenance costs, and type of economic dependencies are functions of operating modes. In each operating mode, the decision maker should decide on the set of units to activate (usage decision) and the set of units to maintain (maintenance decision). Since the degradation rate differs for active and standby units, the units to be maintained depend on the units that have been activated, and vice versa. In order to minimize maintenance costs, usage and maintenance decisions should be jointly optimized. We formulate this problem as a Markov decision process and provide some structural properties of the optimal policy. Moreover, we assess the performance of usage policies that are commonly implemented for maritime systems. We show that the cost increase resulting from these policies is up to 27% for realistic settings. Our numerical experiments demonstrate the cases in which joint usage and maintenance optimization is more valuable. © 2017 Wiley Periodicals, Inc. Naval Research Logistics 64: 418–434, 2017     

Replacement models under additive damage

A production system which generates income is subject to random failure. Upon failure, the system is replaced by a new identical one and the replacement cycles are repeated indefinitely. In our breakdown model, shocks occur to the system in a Poisson stream. Each shock causes a random amount of damage, and these damages accumulate additively. The failure time depends on the accumulated damage in the system. The income from the system and the cost associated with a planned replacement depend on the accumulated damage in the system. An additional cost is incurred at each failure in service. We allow a controller to replace the system at any stopping time T before failure time. We will consider the problem of specifying a replacement rule that is optimal under the following criteria: maximum total long-run average net income per unit time, and maximum total long-run expected discounted net income. Our primary goal is to introduce conditions under which an optimal policy is a control limit policy and to investigate how the optimal policy can be obtained. Examples will be presented to illustrate computational procedures.     

Optimal control policies for an inventory system with commitment lead time

We consider a firm which faces a Poisson customer demand and uses a base‐stock policy to replenish its inventories from an outside supplier with a fixed lead time. The firm can use a preorder strategy which allows the customers to place their orders before their actual need. The time from a customer's order until the date a product is actually needed is called commitment lead time. The firm pays a commitment cost which is strictly increasing and convex in the length of the commitment lead time. For such a system, we prove the optimality of bang‐bang and all‐or‐nothing policies for the commitment lead time and the base‐stock policy, respectively. We study the case where the commitment cost is linear in the length of the commitment lead time in detail. We show that there exists a unit commitment cost threshold which dictates the optimality of either a buy‐to‐order (BTO) or a buy‐to‐stock strategy. The unit commitment cost threshold is increasing in the unit holding and backordering costs and decreasing in the mean lead time demand. We determine the conditions on the unit commitment cost for profitability of the BTO strategy and study the case with a compound Poisson customer demand.     

Optimal control policies in service systems with limited information on the downstream stage

Existing models in multistage service systems assume full information on the state of downstream stages. In this paper, we investigate how much the lack of such information impacts jobs' waiting time in a two‐stage system with two types of jobs at the first stage. The goal is to find the optimal control policy for the server at the first stage to switch between type‐1 and type‐2 jobs, while minimizing the long‐run average number of jobs in the system. We identify control policies and corresponding conditions under which having no or partial information, the system can still capture the most benefit of having full information.     

Nonrobustness of the normal approximation of lead‐time demand in a (Q,R) system

For computing an optimal (Q, R) or kindred inventory policy, the current literature provides mixed signals on whether or when it is safe to approximate a nonnormal lead‐time‐demand (“LTD”) distribution by a normal distribution. The first part of this paper examines this literature critically to justify why the issue warrants further investigations, while the second part presents reliable evidence showing that the system‐cost penalty for using the normal approximation can be quite serious even when the LTD‐distribution's coefficient of variation is quite low—contrary to the prevalent view of the literature. We also identify situations that will most likely lead to large system‐cost penalty. Our results indicate that, given today's technology, it is worthwhile to estimate an LTD‐distribution's shape more accurately and to compute optimal inventory policies using statistical distributions that more accurately reflect the LTD‐distributions' actual shapes. © 2003 Wiley Periodicals, Inc. Naval Research Logistics, 2003     

Quantity discount pricing policies for heterogeneous retailers with price sensitive demand

Although quantity discount policies have been extensively analyzed, they are not well understood when there are many different buyers. This is especially the case when buyers face price‐sensitive demand. In this paper we study a supplier's optimal quantity discount policy for a group of independent and heterogeneous retailers, when each retailer faces a demand that is a decreasing function of its retail price. The problem is analyzed as a Stackelberg game whereby the supplier acts as the leader and buyers act as followers. We show that a common quantity discount policy that is designed according to buyers' individual cost and demand structures and their rational economic behavior is able to significantly stimulate demand, improve channel efficiency, and substantially increase profits for both the supplier and buyers. Furthermore, we show that the selection of all‐units or incremental quantity discount policies has no effect on the benefits that can be obtained from quantity discounts. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Technical note: Reexamination of all‐or‐none inspection policies in a supply chain with endogenous product quality

This note studies the optimal inspection policies in a supply chain in which a manufacturer purchases components from a supplier but has no direct control of component quality. The manufacturer uses an inspection policy and a damage cost sharing contract to encourage the supplier to improve the component quality. We find that all‐or‐none inspection policies are optimal for the manufacturer if the supplier's share of the damage cost is larger than a threshold; otherwise, the manufacturer should inspect a fraction of a batch. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

Value added analysis for army equipment modernization

This paper describes the Value Added Analysis methodology which is used as part of the U.S. Army's Planning, Programming, Budgeting, and Execution System to assist the Army leadership in evaluating and prioritizing competing weapon system alternatives during the process of building the Army budget. The Value Added Analysis concept uses a family of models to estimate an alternative system's contribution to the Army's effectiveness using a multiattribute value hierarchy. A mathematical optimization model is then used to simultaneously determine an alternative's cost‐benefit and to identify an optimal mix of weapon systems for inclusion in the Army budget. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 233–253, 1999