Optimal lot sizing and inspection policy for an EMQ model with imperfect inspections

An EMQ model with a production process subject to random deterioration is considered. The process can be monitored through inspections, and both the lot size and the inspection schedule are subject to control. The “in-control” periods are assumed to be generally distributed and the inspections are imperfect, i.e., the true state of the process is not necessarily revealed through an inspection. The objective is the joint determination of the lot size and the inspection schedule, minimizing the long-run expected average cost per unit time. Both discrete and continuous cases are examined. A dynamic programming formulation is considered in the case where the inspections can be performed only at discrete times, which is typical for the parts industry. In the continuous case, an optimum inspection schedule is obtained for a given production time and given number of inspections by solving a nonlinear programming problem. A two-dimensional search procedure can be used to find the optimal policy. In the exponential case, the structure of the optimal inspection policy is established using Lagrange's method, and it is shown that the optimal inspection times can be found by solving a nonlinear equation. Numerical studies indicate that the optimal policy performs much better than the optimal policy with periodic inspections considered previously in the literature. The case of perfect inspections is discussed, and an extension of the results obtained previously in the literature is presented. © 1998 John Wiley & Sons, Inc. Naval Research Logistics 45: 165–186, 1998     

Optimal accelerated life test designs for Burr type XII distributions under periodic inspection and type I censoring

This article develops optimal accelerated life test designs for Burr Type XII distributions under periodic inspection and Type I censoring. It is assumed that the mean lifetime (the Burr XII scale parameter) is a log-linear function of stress and that the shape parameters are independent of stress. For given shape parameters, design stress and high test stress, the test design is optimized with respect to the low test stress and the proportion of test units allocated to the low stress. The optimality criterion is the asymptotic variance of the maximum-likelihood estimator of log mean life at the design stress with the use of equally spaced inspection times. Computational results for various values of the shape parameters show that this criterion is insensitive to the number of inspection times and to misspecification of imputed failure probabilities at the design and high test stresses. Procedures for planning an accelerated life test, including selection of sample size, are also discussed. It is shown that optimal designs previously obtained for exponential and Weibull distributions are similar to those obtained here for the appropriate special cases of the Burr XII distribution. Thus the Burr XII distribution is a useful and widely applicable family of reliability models for ALT design. © 1996 John Wiley & Sons, Inc.     

Optimal control of entry to an M/Ek/1 queue serving several classes of customers

The individual and social optimum control policies for entry to an M/M//1 queue serving several classes of customers have been shown to be control-limit policies. The technique of policy iteration provides the social optimum policy for such a queue in a straightforward manner. In this article, the problem of finding the optimal control policy for the M/E_k/1 system is solved, thereby expanding the potential applicability of the solutions developed. The Markovian nature of the queueing system is preserved by considering the service as having k sequential phases, each with independent, identically distributed, exponential service times, through which a customer must pass to be serviced. The optimal policy derived by policy iteration for such a system is likely to be difficult to use because it requires knowledge of the number of phases rather than customers in the system when an arrival occurs. To circumvent this difficulty, a heuristic is used to find a good usable (implementable) solution. In addition, a mixed-integer program is developed which yields the optimal implementable solution when solved.     

Bayesian estimation and optimal designs in partially accelerated life testing

A method of life testing is proposed which combines both ordinary and accelerated life-testing procedures. It is assumed that an item can be tested either in a standard environment or under stress. The amount of stress is fixed in advance and is the same for all items to be tested However, the time x at which an item on lest is taken out of the standard environment and put under stress can be chosen by the experimenter subject to a given cost structure. When an item is put under stress its lifetime is changed by the factor α. Let the random variable T denote the lifetime of an item in the standard environment, and let γ denote its lifetime under the partially accelerated test procedure just described. Then Y = T if T ≦ x, and Y = x + α (T > x) if T > x. It is assumed that T has an exponential distribution with parameter θ. The estimation of θ and α and the optimal design of a partially accelerated life test are studied in the framework of Bayesian decision theory.     

Optimal replacement of parts having observable correlated stages of deterioration

A single component system is assumed to progress through a finite number of increasingly bad levels of deterioration. The system with level i (0 ≤ i ≤ n) starts in state 0 when new, and is definitely replaced upon reaching the worthless state n. It is assumed that the transition times are directly monitored and the admissible class of strategies allows substitution of a new component only at such transition times. The durations in various deterioration levels are dependent random variables with exponential marginal distributions and a particularly convenient joint distribution. Strategies are chosen to maximize the average rewards per unit time. For some reward functions (with the reward rate depending on the state and the duration in this state) the knowledge of previous state duration provides useful information about the rate of deterioration.     

Periodic inspection policy with preventive maintenance

This article considers a modified inspection policy with periodic check intervals, where the unit after check has the same age as before with probability p and is as good as new with probability q. The mean time to failure and the expected number of checks before failure are derived, forming renewal-type equations. The total expected cost and the expected cost per unit of time until detection of failure are obtained. Optimum inspection policies which minimize the expected costs are given as a numerical example.     

The incentive effect of acceptance sampling plans in a supply chain with endogenous product quality

This article studies a firm that procures a product from a supplier. The quality of each product unit is measured by a continuous variable that follows a normal distribution and is correlated within a batch. The firm conducts an inspection and pays the supplier only if the product batch passes the inspection. The inspection not only serves the purpose of preventing a bad batch from reaching customers but also offers the supplier an incentive to improve product quality. The firm determines the acceptance sampling plan, and the supplier determines the quality effort level in either a simultaneous game or a Stackelberg leadership game, in which both parties share inspection cost and recall loss caused by low product quality. In the simultaneous game, we identify the Nash equilibrium form, provide sufficient conditions that guarantee the existence of a pure strategy Nash equilibrium, and find parameter settings under which the decentralized and centralized supply chains achieve the same outcome. By numerical experiments, we show that the firm's acceptance sampling plan and the supplier's quality effort level are sensitive to both the recall loss sharing ratio and the game format (i.e., the precommitment assumption of the inspection policy). © 2013 Wiley Periodicals, Inc. Naval Research Logistics, 2013     

MAD: Mathematical analysis of downtime

The MAD model presents a mathematic treatment of the relationship between aircraft reliability and maintainability, system manning and inspection policies, scheduling and sortie length, and aircraft downtime. Log normal distributions are postulated for subsystem repair times and simultaneous repair of malfunctions is assumed. The aircraft downtime for maintenance is computed with the distribution of the largest of k log normal distributions. Waiting time for maintenance men is calculated either by using a multiple-channel queuing model or by generating the distribution of the number of maintenance men required and comparing this to the number of men available to determine the probability of waiting at each inspection.     

Scheduling of stochastic tasks on two parallel processors

We consider the problem of scheduling n tasks on two identical parallel processors. We show both in the case when the processing times for the n tasks are independent exponential random variables, and when they are independent hyperexponentials which are mixtures of two fixed exponentials, that the policy of performing tasks with longest expected processing time (LEPT) first minimizes the expected makespan, and that in the hyperexponential case the policy of performing tasks with shortest expected processing time (SEPT) first minimizes the expected flow time. The approach is simpler than the dynamic programming approach recently employed by Bruno and Downey.     

MARKOVIAN DETERIORATION WITH UNCERTAIN INFORMATION — A MORE GENERAL MODEL

A model of a deteriorating system with imperfect information is considered. The structures appropriate for such a model include failing machinery and depleted inventory systems. In an effort to add a new dimension to such models, it is assumed that the operator must pay an inspection cost to determine the precise state of the system. At the start of every time period, the operator is faced with three choices: repair, no action, or inspection. Under fairly general assumptions, the optimal policy for repair is found to be straightforward and intuitive. This result has two important areas of application.     

Efficient distributions of arms‐control inspection effort

A rule that constrains decision‐makers is enforced by an inspector who is supplied with a fixed level of inspection resources—inspection personnel, equipment, or time. How should the inspector distribute its inspection resources over several independent inspectees? What minimum level of resources is required to deter all violations? Optimal enforcement problems occur in many contexts; the motivating application for this study is the role of the International Atomic Energy Agency in support of the Treaty on the Non‐Proliferation of Nuclear Weapons. Using game‐theoretic models, the resource level adequate for deterrence is characterized in a two‐inspectee problem with inspections that are imperfect in the sense that violations can be missed. Detection functions, or probabilities of detecting a violation, are assumed to be increasing in inspection resources, permitting optimal allocations over inspectees to be described both in general and in special cases. When detection functions are convex, inspection effort should be concentrated on one inspectee chosen at random, but when they are concave it should be spread deterministicly over the inspectees. Our analysis provides guidance for the design of arms‐control verification operations, and implies that a priori constraints on the distribution of inspection effort can result in significant inefficiencies. © 2003 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

An integral equation for the second moment function of a geometric process and its numerical solution

In this article, an integral equation satisfied by the second moment function M₂(t) of a geometric process is obtained. The numerical method based on the trapezoidal integration rule proposed by Tang and Lam for the geometric function M(t) is adapted to solve this integral equation. To illustrate the numerical method, the first interarrival time is assumed to be one of four common lifetime distributions, namely, exponential, gamma, Weibull, and lognormal. In addition to this method, a power series expansion is derived using the integral equation for the second moment function M₂(t), when the first interarrival time has an exponential distribution.     

Markovian approximation for manufacturing systems of unreliable machines in tandem

This paper studies production planning of manufacturing systems of unreliable machines in tandem. The manufacturing system considered here produces one type of product. The demand is assumed to be a Poisson process and the processing time for one unit of product in each machine is exponentially distributed. A broken machine is subject to a sequence of repairing processes. The up time and the repairing time in each phase are assumed to be exponentially distributed. We study the manufacturing system by considering each machine as an individual system with stochastic supply and demand. The Markov Modulated Poisson Process (MMPP) is applied to model the process of supply. Numerical examples are given to demonstrate the accuracy of the proposed method. We employ (s, S) policy as production control. Fast algorithms are presented to solve the average running costs of the machine system for a given (s, S) policy and hence the approximated optimal (s, S) policy. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48: 65–78, 2001     

Analysis of a machine repair problem with an unreliable server and phase type repairs and services

In this paper we study a machine repair problem in which a single unreliable server maintains N identical machines. The breakdown times of the machines are assumed to follow an exponential distribution. The server is subject to failure and the failure times are exponentially distributed. The repair times of the machine and the service times of the repairman are assumed to be of phase type. Using matrix‐analytic methods, we perform steady state analysis of this model. The time spent by a failed machine in service and the total time in the repair facility are shown to be of phase type. Several performance measures are evaluated. An optimization problem to determine the number of machines to be assigned to the server that will maximize the expected total profit per unit time is discussed. An illustrative numerical example is presented. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 462–480, 2003     

Optimal burn‐in procedure for periodically inspected systems

Burn‐in is a widely used method to improve the quality of products or systems after they have been produced. In this paper, we study burn‐in procedure for a system that is maintained under periodic inspection and perfect repair policy. Assuming that the underlying lifetime distribution of a system has an initially decreasing and/or eventually increasing failure rate function, we derive upper and lower bounds for the optimal burn‐in time, which maximizes the system availability. Furthermore, adopting an age replacement policy, we derive upper and lower bounds for the optimal age parameter of the replacement policy for each fixed burn‐in time and a uniform upper bound for the optimal burn‐in time given the age replacement policy. These results can be used to reduce the numerical work for determining both optimal burn‐in time and optimal replacement policy. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Stochastic allocation of inspection capacity to competitive processes

Optimal allocation and control of limited inspection capacity for multiple production processes are considered. The production processes, which operate independently but share inspection capacity, are subject to random failures and are partially observed through inspection. This study proposes an approach of stochastic allocation, using a Markov decision process, to minimize expected total discounted cost over an infinite time horizon. Both an optimal model and a disaggregate approximation model are introduced. The study provides some structural results and establishes that the control policy is of a threshold type. Numerical experiments demonstrate a significantly decreased amount of computational time required for the disaggregate approach when compared to the optimal solution, while generating very good control policies. © 2002 John Wiley & Sons, Inc. Naval Research Logistics, 49: 78–94, 2002; DOI 10.1002/nav.1049     

Economic screening procedures in logistic and normal models

Economic screening procedures based on a continuous screening variable X in place of a dichotomous performance variable T are presented. Optimal critical values on the screening variable minimizing the expected cost are obtained for two models; it is assumed that X given T is normally distributed in normal model and P[T = 1|X] is a logistic function of X in the logistic model, and that costs are incurred by screening inspection and misclassification errors. Cases where some parameters are unknown are also considered.     

An economic two-stage screening procedure with a prescribed outgoing quality in logistic and normal models

An economic two-stage screening procedure based on a dichotomous performance variable T and a continuous screening variable X is proposed. X is measured first to decide whether an item should be accepted, rejected, or additional observations should be taken. If no terminal decision is reached, T is then observed to classify the undecided items. Two models are considered; (i) the logistic model, where P(T = 1|X = x) is assumed to be a logistic function of x, and (ii) the normal model, where X given T is assumed to be normally distributed. A simple economic model based on inspection and misclassification costs is constructed. Optimal cutoff values on the screening variable are obtained by minimizing the expected cost subject to the constraint that the average outgoing quality attains a pre-specified level. Solutions are provided for both known-parameter and unknown-parameter cases. © 1995 John Wiley & Sons, Inc.     

Periodic replacement when minimal repair costs vary with time

A policy of periodic replacement with minimal repair at failure is considered for a complex system. Under such a policy the system is replaced at multiples of some period T while minimal repair is performed at any intervening system failures. The cost of a minimal repair to the system is assumed to be a nonde-creasing function of its age. A simple expression is derived for the expected minimal repair cost in an interval in terms of the cost function and the failure rate of the system. Necessary and sufficient conditions for the existence of an optimal replacement interval are exhibited in the case where the system life distribution is strictly increasing failure rate (IFR).