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.     

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     

Scheduling economic lot sizes in deteriorating production systems

The paper considers the economic lot scheduling problem (ELSP) where production facility is assumed to deteriorate, owing to aging, with an increasing failure rate. The time to shift from an “in‐control” state to an “out‐of‐control” state is assumed to be normally distributed. The system is scheduled to be inspected at the end of each production lot. If the process is found to be in an “out‐of‐control” state, then corrective maintenance is performed to restore it to an “in‐control” state before the start of the next production run. Otherwise, preventive maintenance is carried out to enhance system reliability. The ELSP is formulated under the capacity constraint taking into account the quality related cost due to possible production of non‐conforming items, process inspection, and maintenance costs. In order to find a feasible production schedule, both the common cycle and time‐varying lot sizes approaches are utilized. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 650–661, 2003     

Using stochastic programming to solve an outpatient appointment scheduling problem with random service and arrival times

We study a stochastic outpatient appointment scheduling problem (SOASP) in which we need to design a schedule and an adaptive rescheduling (i.e., resequencing or declining) policy for a set of patients. Each patient has a known type and associated probability distributions of random service duration and random arrival time. Finding a provably optimal solution to this problem requires solving a multistage stochastic mixed‐integer program (MSMIP) with a schedule optimization problem solved at each stage, determining the optimal rescheduling policy over the various random service durations and arrival times. In recognition that this MSMIP is intractable, we first consider a two‐stage model (TSM) that relaxes the nonanticipativity constraints of MSMIP and so yields a lower bound. Second, we derive a set of valid inequalities to strengthen and improve the solvability of the TSM formulation. Third, we obtain an upper bound for the MSMIP by solving the TSM under the feasible (and easily implementable) appointment order (AO) policy, which requires that patients are served in the order of their scheduled appointments, independent of their actual arrival times. Fourth, we propose a Monte Carlo approach to evaluate the relative gap between the MSMIP upper and lower bounds. Finally, in a series of numerical experiments, we show that these two bounds are very close in a wide range of SOASP instances, demonstrating the near‐optimality of the AO policy. We also identify parameter settings that result in a large gap in between these two bounds. Accordingly, we propose an alternative policy based on neighbor‐swapping. We demonstrate that this alternative policy leads to a much tighter upper bound and significantly shrinks the gap.     

Simultaneous price,location, and capacity decisions on a line of time‐sensitive customers

Consider a monopolist who sells a single product to time‐sensitive customers located on a line segment. Customers send their orders to the nearest distribution facility, where the firm processes (customizes) these orders on a first‐come, first‐served basis before delivering them. We examine how the monopolist would locate its facilities, set their capacities, and price the product offered to maximize profits. We explicitly model customers' waiting costs due to both shipping lead times and queueing congestion delays and allow each customer to self‐select whether she orders or not, based on her reservation price. We first analyze the single‐facility problem and derive a number of interesting insights regarding the optimal solution. We show, for instance, that the optimal capacity relates to the square root of the customer volume and that the optimal price relates additively to the capacity and transportation delay costs. We also compare our solutions to a similar problem without congestion effects. We then utilize our single‐facility results to treat the multi‐facility problem. We characterize the optimal policy for serving a fixed interval of customers from multiple facilities when customers are uniformly distributed on a line. We also show how as the length of the customer interval increases, the optimal policy relates to the single‐facility problem of maximizing expected profit per unit distance. © 2006 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Integrated production scheduling and preventive maintenance planning for a single machine under a cumulative damage failure process

This paper finds the optimal integrated production schedule and preventive maintenance plan for a single machine exposed under a cumulative damage process, and investigates how the optimal preventive maintenance plan interacts with the optimal production schedule. The goal is to minimize the total tardiness. The optimal policy possesses the following properties: Under arbitrary maintenance plan when jobs have common processing time, and different due dates, the optimal production schedule is to order the jobs by earliest due date first rule; and when jobs have common due date and different processing times, the optimal production schedule is shortest processing time first. The optimal maintenance plan is of control limit type under any arbitrary production schedule when machine is exposed under a cumulative damage failure process. Numerical studies on the optimal maintenance control limit of the maintenance plan indicate that as the number of jobs to be scheduled increases, the effect of jobs due dates on the optimal maintenance control limit diminishes. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Nonperiodic preventive maintenance for repairable systems

As a complex system with multiple components usually deteriorates with age, preventive maintenance (PM) is often performed to keep the system functioning in a good state to prolong its effective age. In this study, a nonhomogeneous Poisson process with a power law failure intensity is used to describe the deterioration of a repairable system, and the optimal nonperiodic PM schedule can be determined to minimize the expected total cost per unit time. However, since the determination of such optimal PM policies may involve numerous uncertainties, which typically make the analyses difficult to perform because of the scarcity of data, a Bayesian decision model, which utilizes all available information effectively, is also proposed for determining the optimal PM strategies. A numerical example with a real failure data set is used to illustrate the effectiveness of the proposed approach. The results show that the optimal schedules derived by Bayesian approach are relatively more conservative than that for non‐Bayesian approach because of the uncertainty of the intensity function, and if the intensity function are updated using the collected data set, which indicates more severe deterioration than the prior belief, replacing the entire system instead of frequent PM activities before serious deterioration is suggested. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

An optimum group maintenance policy

In this article we present an optimum maintenance policy for a group of machines subject to stochastic failures where the repair cost and production loss due to the breakdown of machines are minimized. A nomograph was developed for machines with exponential failure time distributions. The optimal schedule time for repair as well as the total repair cost per cycle can be obtained easily from the nomograph. Conditions for the existence of a unique solution for the optimum schedule and the bounds for the schedule are discussed.     

Decentralized admission control of a queueing system: A game‐theoretic model

Consider a distributed system where many gatekeepers share a single server. Customers arrive at each gatekeeper according to independent Poisson processes with different rates. Upon arrival of a new customer, the gatekeeper has to decide whether to admit the customer by sending it to the server, or to block it. Blocking costs nothing. The gatekeeper receives a reward after a customer completes the service, and incurs a cost if an admitted customer finds a busy server and therefore has to leave the system. Assuming an exponential service distribution, we formulate the problem as an n‐person non‐zero‐sum game in which each gatekeeper is interested in maximizing its own long‐run average reward. The key result is that each gatekeeper's optimal policy is that of a threshold type regardless what other gatekeepers do. We then derive Nash equilibria and discuss interesting insights. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 702–718, 2003.     

Simultaneous production of market‐specific and global products: A two‐stage stochastic program with additional demand after recourse

This paper analyzes the simultaneous production of market‐specific products tailored to the needs of individual regions and a global product that could be sold in many regions. We assume that the global product costs more to manufacture, but allows the decision concerning the allocation of products to regions to be delayed until after the manufacturing process has been completed. We further assume that there is additional demand after the region allocation but prior to delivery, extending the two‐stage stochastic program with recourse to include additional stochastic demand after the recourse. This scenario arises, for example, when there is additional uncertainty during a delivery delay which might occur with transoceanic shipments. We develop conditions for optimality assuming a single build‐allocate‐deliver cycle and stochastic demand during both the build and deliver periods. The optimal policy calls for the simultaneous production of market‐specific and global products, even when the global product is substantially more costly than the market‐specific product. In addition, we develop bounds on the performance of the optimal policy for the multicycle problem. © 2003 Wiley Periodicals, Inc. Naval Research Logistics 50: 438–461, 2003     

Dynamic lot‐sizing model with production time windows

We consider a dynamic lot‐sizing model with production time windows where each of n demands has earliest and latest production due dates and it must be satisfied during the given time window. For the case of nonspeculative cost structure, an O(nlogn) time procedure is developed and it is shown to run in O(n) when demands come in the order of latest production due dates. When the cost structure is somewhat general fixed plus linear that allows speculative motive, an optimal procedure with O(T⁴) is proposed where T is the length of a planning horizon. Finally, for the most general concave production cost structure, an optimal procedure with O(T⁵) is designed. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Force deployment and the production of security: Why is the united states in NATO?

Standard economic concepts of production and cost minimization subject to a production constraint are used to derive the conditions of optimal deployment of home and forward military forces for the production of home security. United States' participation in the NATO alliance is then analyzed in the context of a two‐ally (U.S. and Western Europe) optimal force deployment model of NATO. Next, U.S. force‐basing policy is adduced as an enforcement mechanism for the “transatlantic contract.” Lastly, statistical evidence on burden sharing within Western Europe, and the effectiveness of the U.S. contract enforcement policy, is presented.     

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.     

Bayesian enhanced decision making for deteriorating repairable systems with preventive maintenance

Since a system and its components usually deteriorate with age, preventive maintenance (PM) is often performed to restore or keep the function of a system in a good state. Furthermore, PM is capable of improving the health condition of the system and thus prolongs its effective age. There has been a vast amount of research to find optimal PM policies for deteriorating repairable systems. However, such decisions involve numerous uncertainties and the analyses are typically difficult to perform because of the scarcity of data. It is therefore important to make use of all information in an efficient way. In this article, a Bayesian decision model is developed to determine the optimal number of PM actions for systems which are maintained according to a periodic PM policy. A non‐homogeneous Poisson process with a power law failure intensity is used to describe the deteriorating behavior of the repairable system. It is assumed that the status of the system after a PM is somewhere between as good as new for a perfect repair and as good as old for a minimal repair, and for failures between two preventive maintenances, the system undergoes minimal repairs. Finally, a numerical example is given and the results of the proposed approach are discussed after performing sensitivity analysis. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

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).     

On the treatment of force-level constraints in times-equential combat problems

The treatment of force-level constraints in time-sequential combat optimization problems is illustrated by further studying the fire-programming problem of Isbell and Marlow. By using the theory of state variable inequality constraints from modern optimal control theory, sharper results are obtained on necessary conditions of optimality for an optimal fire-distribution policy (in several cases justifying conjectures made in previous analysis). This leads to simplification of the determination of the domains of controllability for extremals leading to the various terminal states of combat. (Additionally, some new results for the determination of boundary conditions for the adjoint variables in optimal control problems with state variable inequality constraints have arisen from this work.) Some further extensions of previous analysis of the fire-programming problem are also given. These clarify some key points in the solution synthesis. Some important military principles for target selection and the valuation of combat resources are deduced from the solution. As a result of this work, more general time-sequential combat optimization problems can be handled, and a more systematic solution procedure is developed.     

A worst‐case formulation for constrained ranking and selection with input uncertainty

In this research, we consider robust simulation optimization with stochastic constraints. In particular, we focus on the ranking and selection problem in which the computing time is sufficient to evaluate all the designs (solutions) under consideration. Given a fixed simulation budget, we aim at maximizing the probability of correct selection (PCS) for the best feasible design, where the objective and constraint measures are assessed by their worst‐case performances. To simplify the complexity of PCS, we develop an approximated probability measure and derive the asymptotic optimality condition (optimality condition as the simulation budget goes to infinity) of the resulting problem. A sequential selection procedure is then designed within the optimal computing budget allocation framework. The high efficiency of the proposed procedure is tested via a number of numerical examples. In addition, we provide some useful insights into the efficiency of a budget allocation procedure.     

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.     

Interval estimation of a global optimum for large combinatorial problems

Consider an “intractable” optimization problem for which no efficient solution technique exists. Given a systematic procedure for generating independent heuristic solutions, we seek to obtain interval estimates for the globally optimal solution using statistical inference. In previous work, accurate point estimates have been derived. Determining interval estimates, however, is a considerably more difficult task. In this paper, we develop straightforward procedures which compute confidence intervals efficiently in order to evaluate heuristic solutions and assess deviations from optimality. The strategy presented is applicable to a host of combinatorial optimization problems. The assumptions of our model, along with computational experience, are discussed.