Planning horizon procedures for machine replacement models with several possible replacement alternatives

This paper develops a forward algorithm and planning horizon procedures for an important machine replacement model where it is assumed that the technological environment is improving over time and that the machine-in-use can be replaced by any of the several different kinds of machines available at that time. The set of replacement alternatives may include (i) new machines with different types of technologies such as labor- and capital- intensive, (ii) used machines, (iii) repairs and/or improvements which affect the performance characteristics of the existing machine, and so forth. The forward dynamic programming algorithm in the paper can be used to solve a finite horizon problem. The planning horizon results give a procedure to identify the forecast horizon T such that the optimal replacement decision for the first machine based on the forecast of machine technology until period T remains optimal for any problem with horizon longer than T and, for that matter, for the infinite horizon problem. A flow chart and a numerical example have been included to illustrate the algorithm.     

Optimal maintenance-repair policies for the machine repair problem

We consider a model with M + N identical machines. As many as N of these can be working at any given time and the others act as standby spares. Working machines fail at exponential rate λ, spares fail at exponential rale γ, and failed machines are repaired at exponential rate μ. The control variables are λ. μ, and the number of removable repairman, S, to be operated at any given time. Using the criterion of total expected discounted cost, we show that λ, S, and μ are monotonic functions of the number of failed machines M, N, the discount factor, and for the finite time horizon model, the amount of time remaining.     

A parallel machine replacement model

This paper considers a finite horizon parallel machine replacement problem where a fixed number of machines is in operation at all times. The operating cost for a machine goes up as the machine gets older. An older machine may have to be replaced by a new one when its operating cost becomes too high. There is a fixed order cost associated with the purchase of new machines. Machine purchase prices and salvage values may depend on the period in which they were purchased. The objective is to find a replacement plan that minimizes the total discounted cost over the problem horizon. We believe that the costs in our model are more commonly observed in practice than those previously used in the literature. The paper develops properties of optimal solutions and an efficient forward‐time algorithm to find an optimal replacement plan. A dominance property is developed that further limits the options to be considered, and a simple forecast horizon result is also presented. Future research possibilities are mentioned. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 275–287, 2002; Published online in Wiley InterScience (http://www.interscience.wiley.com). DOI 10.1002/nav.10012     

Scheduling parallel dedicated machines with the speeding‐up resource

We consider a problem of scheduling jobs on m parallel machines. The machines are dedicated, i.e., for each job the processing machine is known in advance. We mainly concentrate on the model in which at any time there is one unit of an additional resource. Any job may be assigned the resource and this reduces its processing time. A job that is given the resource uses it at each time of its processing. No two jobs are allowed to use the resource simultaneously. The objective is to minimize the makespan. We prove that the two‐machine problem is NP‐hard in the ordinary sense, describe a pseudopolynomial dynamic programming algorithm and convert it into an FPTAS. For the problem with an arbitrary number of machines we present an algorithm with a worst‐case ratio close to 3/2, and close to 3, if a job can be given several units of the resource. For the problem with a fixed number of machines we give a PTAS. Virtually all algorithms rely on a certain variant of the linear knapsack problem (maximization, minimization, multiple‐choice, bicriteria). © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

Optimal renewal policies for complex systems

Most maintenance and replacement models for industrial equipment have been developed for independent single-component machines. Most equipment, however, consists of multiple components. Also, when the maintenance crew services several machines, the maintenance policy for each machine is not independent of the states of the other machines. In this paper, two dynamic programming replacement models are presented. The first is used to determine the optimal replacement policy for multi-component equipment. The second is used to determine the optimal replacement policy for a multi-machine system which uses one replacement crew to service several machines. In addition, an approach is suggested for developing an efficient replacement policy for a multi-component, multi-machine system.     

A dynamic nonlinear constrained optimal replacement model

A stochastically constrained optimal replacement model for capital equipment is constructed. Each piece of capital equipment, or machine, is characterized by its age and “utility” or “readiness” class. The readiness of a machine at any age is a stochastic function of its initial utility class and its age. The total discounted replacement cost of several replacement streams, each commencing with an initial machine, is minimized with respect to the replacement age and initial utility class of each machine, subject to a readiness constraint stating the lower bound on the expected number of machines in each utility class at any time. A general solution procedure is outlined and a specific case is solved in detail.     

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     

Monotone optimal preventive maintenance policies for stochastically failing equipment

This paper examines various models for maintenance of a machine operating subject to stochastic deterioration. Three alternative models are presented for the deterioration process. For each model, in addition to the replacement decision, the option exists of performing preventive maintenance. The effect of this maintenance is to “slow” the deterioration process. With an appropriate reward structure imposed on the processes, the models are formulated as continuous time Markov decision processes. the optimality criterion being the maximization of expected discounted reward earned over an infinite time horizon. For each model conditions are presented under which the optimal maintenance policy exhibits the following monotonic structure. First, there exists a control limit rule for replacement. That is, there exists a number i* such that if the state of machine deterioration exceeds i* the optimal policy replaces the machine by a new machine. Secondly, prior to replacement the optimal level of preventive maintenance is a nonincreasing function of the state of machine deterioration. The conditions which guarantee this result have a cost/benefit interpretation.     

On parallel machine replacement problems with general replacement cost functions and stochastic deterioration

The parallel machine replacement problem consists of finding a minimum cost replacement policy for a finite population of economically interdependent machines. In this paper, we formulate a stochastic version of the problem and analyze the structure of optimal policies under general classes of replacement cost functions. We prove that for problems with arbitrary cost functions, there can be optimal policies where a machine is replaced only if all machines in worse states are replaced (Worse Cluster Replacement Rule). We then show that, for problems with replacement cost functions exhibiting nonincreasing marginal costs, there are optimal policies such that, in any stage, machines in the same state are either all kept or all replaced (No‐Splitting Rule). We also present an example that shows that economies of scale in replacement costs do not guarantee optimal policies that satisfy the No‐Splitting Rule. These results lead to the fundamental insight that replacement decisions are driven by marginal costs, and not by economies of scale as suggested in the literature. Finally, we describe how the optimal policy structure, i.e., the No‐Splitting and Worse Cluster Replacement Rules, can be used to reduce the computational effort required to obtain optimal replacement policies. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2005     

Scheduling jobs and maintenance activities on parallel machines

Most machine scheduling models assume that the machines are available all of the time. However, in most realistic situations, machines need to be maintained and hence may become unavailable during certain periods. In this paper, we study the problem of processing a set of n jobs on m parallel machines where each machine must be maintained once during the planning horizon. Our objective is to schedule jobs and maintenance activities so that the total weighted completion time of jobs is minimized. Two cases are studied in this paper. In the first case, there are sufficient resources so that different machines can be maintained simultaneously if necessary. In the second case, only one machine can be maintained at any given time. In this paper, we first show that, even when all jobs have the same weight, both cases of the problem are NP-hard. We then propose branch and bound algorithms based on the column generation approach for solving both cases of the problem. Our algorithms are capable of optimally solving medium sized problems within a reasonable computational time. We note that the general problem where at most j machines, 1 ≤ j ≤ m, can be maintained simultaneously, can be solved similarly by the column generation approach proposed in this paper. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 145–165, 2000     

Quality control chart design under Jidoka

We consider design of control charts in the presence of machine stoppages that are exogenously imposed (as under jidoka practices). Each stoppage creates an opportunity for inspection/repair at reduced cost. We first model a single machine facing opportunities arriving according to a Poisson process, develop the expressions for its operating characteristics and construct the optimization problem for economic design of a control chart. We, then, consider the multiple machine setting where individual machine stoppages may create inspection/repair opportunities for other machines. We develop exact expressions for the cases when all machines are either opportunity‐takers or not. On the basis of an approximation for the all‐taker case, we then propose an approximate model for the mixed case. In a numerical study, we examine the opportunity taking behavior of machines in both single and multiple machine settings and the impact of such practices on the design of an X – Q C chart. Our findings indicate that incorporating inspection/repair opportunities into QC chart design may provide considerable cost savings. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Polynomial‐time approximation scheme for concurrent open shop scheduling with a fixed number of machines to minimize the total weighted completion time

In this article, we consider the concurrent open shop scheduling problem to minimize the total weighted completion time. When the number of machines is arbitrary, the problem has been shown to be inapproximable within a factor of 4/3 ‐ ε for any ε > 0 if the unique games conjecture is true in the literature. We propose a polynomial time approximation scheme for the problem under the restriction that the number of machines is fixed. © 2011 Wiley Periodicals, Inc. Naval Research Logistics, 2011     

Some comparative & design aspects of fixed cycle production systems

A serial production line is defined wherein a unit is produced if, and only if, all machines are functioning. A single buffer stock with finite capacity is to be placed immediately after one of the first N-1 machines in the N machine line. When all machines have equal probability of failure it is shown that the optimal buffer position is exactly in the middle of the line. This result is synthesized with the earlier work of Koenigsberg and Buzacott including an analysis of the covariance between transition states. An alternative model formulation is presented and integrated with previous results. Finally, a sufficient condition and solution procedure is derived for the installation of a buffer where there is a possible trade-off between increasing the reliability of the line versus adding a buffer stock.     

Parallel machine scheduling with batch deliveries to minimize total flow time and delivery cost

Motivated by the flow of products in the iron and steel industry, we study an identical and parallel machine scheduling problem with batch deliveries, where jobs finished on the parallel machines are delivered to customers in batches. Each delivery batch has a capacity and incurs a cost. The objective is to find a coordinated production and delivery schedule that minimizes the total flow time of jobs plus the total delivery cost. This problem is an extension of the problem considered by Hall and Potts, Ann Oper Res 135 (2005) 41–64, who studied a two‐machine problem with an unbounded number of transporters and unbounded delivery capacity. We first provide a dynamic programming algorithm to solve a special case with a given job assignment to the machines. A heuristic algorithm is then presented for the general problem, and its worst‐case performance ratio is analyzed. The computational results show that the heuristic algorithm can generate near‐optimal solutions. Finally, we offer a fully polynomial‐time approximation scheme for a fixed number of machines. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 492–502, 2016     

Scheduling a maintenance activity on parallel identical machines

We study a problem of scheduling a maintenance activity on parallel identical machines, under the assumption that all the machines must be maintained simultaneously. One example for this setting is a situation where the entire system must be stopped for maintenance because of a required electricity shut‐down. The objective is minimum flow‐time. The problem is shown to be NP‐hard, and moreover impossible to approximate unless P = NP. We introduce a pseudo‐polynomial dynamic programming algorithm, and show how to convert it into a bicriteria FPTAS for this problem. We also present an efficient heuristic and a lower bound. Our numerical tests indicate that the heuristic provides in most cases very close‐to‐optimal schedules. © 2008 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Optimal arrangement of systems

To location L_i we are to allocate a “generator” and n_i “machines” for i = 1, …,k, where n₁ … n₁ ≧ … ≧ n_k. Although the generators and machines function independently of one another, a machine is operable only if it and the generator at its location are functioning. The problem we consider is that of finding the arrangement or allocation optimizing the number of operable machines. We show that if the objective is to maximize the expected number of operable machines at some future time, then it is best to allocate the best generator and the n₁ best machines to location L₁, the second-best generator and the n₂-next-best machines to location L₂, etc. However, this arrangement is not always stochastically optimal. For the case of two generators we give a necessary and sufficient condition that this arrangement is stochastically best, and illustrate the result with several examples.     

General multiprocessor task scheduling

Most papers in the scheduling field assume that a job can be processed by only one machine at a time. Namely, they use a one‐job‐on‐one‐machine model. In many industry settings, this may not be an adequate model. Motivated by human resource planning, diagnosable microprocessor systems, berth allocation, and manufacturing systems that may require several resources simultaneously to process a job, we study the problem with a one‐job‐on‐multiple‐machine model. In our model, there are several alternatives that can be used to process a job. In each alternative, several machines need to process simultaneously the job assigned. Our purpose is to select an alternative for each job and then to schedule jobs to minimize the completion time of all jobs. In this paper, we provide a pseudopolynomial algorithm to solve optimally the two‐machine problem, and a combination of a fully polynomial scheme and a heuristic to solve the three‐machine problem. We then extend the results to a general m‐machine problem. Our algorithms also provide an effective lower bounding scheme which lays the foundation for solving optimally the general m‐machine problem. Furthermore, our algorithms can also be applied to solve a special case of the three‐machine problem in pseudopolynomial time. Both pseudopolynomial algorithms (for two‐machine and three‐machine problems) are much more efficient than those in the literature. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 57–74, 1999     

Heuristics for multimachine minmax scheduling problems with general earliness and tardiness costs

We consider the problem of scheduling N jobs on M parallel machines so as to minimize the maximum earliness or tardiness cost incurred for each of the jobs. Earliness and tardiness costs are given by general (but job-independent) functions of the amount of time a job is completed prior to or after a common due date. We show that in problems with a nonrestrictive due date, the problem decomposes into two parts. Each of the M longest jobs is assigned to a different machine, and all other jobs are assigned to the machines so as to minimize their makespan. With these assignments, the individual scheduling problems for each of the machines are simple to solve. We demonstrate that several simple heuristics of low complexity, based on this characterization, are asymptotically optimal under mild probabilistic conditions. We develop attractive worst-case bounds for them. We also develop a simple closed-form lower bound for the minimum cost value. The bound is asymptotically accurate under the same probabilistic conditions. In the case where the due date is restrictive, the problem is more complex only in the sense that the set of initial jobs on the machines is not easily characterized. However, we extend our heuristics and lower bounds to this general case as well. Numerical studies exhibit that these heuristics perform excellently even for small- or moderate-size problems both in the restrictive and nonrestrictive due-date case. © 1997 John Wiley & Sons, Inc.     

The effectiveness of the longest delivery time rule for the flow shop delivery time problem

In the flow shop delivery time problem, a set of jobs has to be processed on m machines. Every machine has to process each one of the jobs, and every job has the same routing through the machines. The objective is to determine a sequence of the jobs on the machines so as to minimize maximum delivery completion time over all the jobs, where the delivery completion time of a job is the sum of its completion time, and the delivery time associated with that job. In this paper, we prove the asymptotic optimality of the Longest Delivery Time algorithm for the static version of this problem, and the Longest Delivery Time among Available Jobs (LDTA) algorithm for the dynamic version of this problem. In addition, we present the result of computational testing of the effectiveness of these algorithms. © 2003 Wiley Periodicals, Inc. Naval Research Logistics, 2003     

Scheduling for parallel dedicated machines with a single server

This paper examines scheduling problems in which the setup phase of each operation needs to be attended by a single server, common for all jobs and different from the processing machines. The objective in each situation is to minimize the makespan. For the processing system consisting of two parallel dedicated machines we prove that the problem of finding an optimal schedule is N P‐hard in the strong sense even if all setup times are equal or if all processing times are equal. For the case of m parallel dedicated machines, a simple greedy algorithm is shown to create a schedule with the makespan that is at most twice the optimum value. For the two machine case, an improved heuristic guarantees a tight worst‐case ratio of 3/2. We also describe several polynomially solvable cases of the later problem. The two‐machine flow shop and the open shop problems with a single server are also shown to be N P‐hard in the strong sense. However, we reduce the two‐machine flow shop no‐wait problem with a single server to the Gilmore—Gomory traveling salesman problem and solve it in polynomial time. © 2000 John Wiley & Sons, Inc. Naval Research Logistics 47: 304–328, 2000