Optimal design of a multi-item,multi-location,multi-repair type repair and supply system

The design of a system with many locations, each with many items which may fail while in use, is considered. When items fail, they require repair; the particular type of repair being governed by a probability distribution. As repairs may be lengthy, spares are kept on hand to replace failed items. System ineffectiveness is measured by expected weighted shortages over all items and locations, in steady state. This can be reduced by either having more spares or shorter expected repair times. Design consists of a provisioning of the number of spares for each item, by location; and specifying the expected repair times for each type of repair, by item and location. The optimal design minimizes expected shortages within a budget constraint, which covers both (i) procurement of spares and (ii) procurement of equipment and manning levels for the repair facilities. All costs are assumed to be separable so that a Lagrangian approach is fruitful, yielding an implementable algorithm with outputs useful for sensitivity analysis. A numerical example is presented.     

Queueing models for spares provisioning

A population of items which break down at random times and require repair is studied (the classic “machine repair problem with spares”). It is desired to determine the number of repair channels and spares required over a multiyear planning horizon in which population size and component reliability varies, and a service level constraint is imposed. When an item fails, a spare (if available) is immediately dispatched to replace the failed item. The failed item is removed, transported to the repair depot, repaired, and then placed in the spares pool (which is constrained to be empty not more than 10% of the time) unless there is a backlog of requests for spares, in which case it is dispatched immediately. The first model considered treats removal, transportation, and repair as one service operation. The second model is a series queue which allows for the separate treatment of removal, transportation, and repair. Breakdowns are assumed Poisson and repair times exponential.     

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 production growth for the machine loading problem

This paper investigates a production growth logistics system for the machine loading problem (generalized transportation model), with a linear cost structure and minimum levels on total machine hours (resources) and product types (demands). An algorithm is provided for tracing the production growth path of this system, viz. in determining the optimal machine loading schedule of machines for product types, when the volumes of (i) total machine hours, and (ii) the total amount of product types are increased either individually for each total or simultaneously for both. Extensions of this methodology, when (i) the costs of production are convex and piecewise linear, and (ii) when the costs are nonconvex due to quantity discounts, and (iii) when there are upper bounds for productions are also discussed. Finally, a “goal-programming” production growth model where the specified demands are treated as just goals and not as absolute quantities to be satisfied is also considered.     

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.     

Optimal machine capacity expansions with nested limitations under stochastic demand

This paper studies capacity expansions for a production facility that faces uncertain customer demand for a single product family. The capacity of the facility is modeled in three tiers, as follows. The first tier consists of a set of upper bounds on production that correspond to different resource types (e.g., machine types, categories of manpower, etc.). These upper bounds are augmented in increments of fixed size (e.g., by purchasing machines of standard types). There is a second‐tier resource that constrains the first‐tier bounds (e.g., clean room floor space). The third‐tier resource bounds the availability of the second‐tier resource (e.g., the total floor space enclosed by the building, land, etc.). The second and third‐tier resources are expanded at various times in various amounts. The cost of capacity expansion at each tier has both fixed and proportional elements. The lost sales cost is used as a measure for the level of customer service. The paper presents a polynomial time algorithm (FIFEX) to minimize the total cost by computing optimal expansion times and amounts for all three types of capacity jointly. It accommodates positive lead times for each type. Demand is assumed to be nondecreasing in a “weak” sense. © 2003 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

Optimal job splitting on a multi‐slot machine with applications in the printing industry

In this article, we define a scheduling/packing problem called the Job Splitting Problem, motivated by the practices in the printing industry. There are n types of items to be produced on an m‐slot machine. A particular assignment of the types to the slots is called a “run” configuration and requires a setup cost. Once a run begins, the production continues according to that configuration and the “length” of the run represents the quantity produced in each slot during that run. For each unit of production in excess of demand, there is a waste cost. Our goal is to construct a production plan, i.e., a set of runs, such that the total setup and waste cost is minimized. We show that the problem is strongly NP‐hard and propose two integer programming formulations, several preprocessing steps, and two heuristics. We also provide a worst‐case bound for one of the heuristics. Extensive tests on real‐world and randomly generated instances show that the heuristics are both fast and effective, finding near‐optimal solutions. © 2010 Wiley Periodicals, Inc. Naval Research Logistics, 2010     

基于神经网络和模糊综合评判的梁故障诊断研究

设计了一个简单的人工智能故障诊断系统模型,它包括知识库、模糊推理、神经网络和控制模块等。模糊推理模块利用模糊综合评判方法进行故障的预诊,神经网络模块采用竞争学习方法完成故障的确诊。文中对悬臂梁的单一故障和复合故障等七种模式进行了诊断分析,均获得了正确的诊断结果。     

The distribution of recoverable inventory items from a repair center when the number of consumption centers is large

This paper considers real-time decision rules for an inventory system where items are repaired than “used up.” The problem is to decide which user in the system has the greatest need for the newly available inventory items coming out of repair. The main result shows that two published approahes, the Transportation Time Look Ahead policy and METRIC, are optimal when the number of users gets large. A useful byproduct of the proof is a lower bound on the average backorder rate for a repair-inventory system of any size.     

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.     

Approximations for the consolidation of multiechelon repair facilities

This paper develops and illustrates an approximate approach for analytically assessing the impacts on both costs and service of consolidation of repair facilities. The repair facilities are two echelon generalizations of the classical repairmen problem in which two types of failures, say major and minor, can occur, each type requiring repair at a different echelon: The questions addressed are the reductions possible in spares, repairmen, and service rates due to the consolidated system's increased efficiency, as well as the physical separation between the users and the consolidated repair facility that is economical. The method of analysis is based upon asymptotic approximations developed for the repairmen problem, valid when the number of operational equipments is large (greater than 50); it is helpful since it provides a tractable means for predicting the steady-state performance of the decentralized and consolidated installations as a function of the many parameters involved without having to resort to an exhaustive computation of all the exact steady-state probabilities.     

On the first time a separately maintained parallel system has been down for a fixed time

Consider a system consisting of n separately maintained independent components where the components alternate between intervals in which they are “up” and in which they are “down”. When the i^th component goes up [down] then, independent of the past, it remains up [down] for a random length of time, having distribution F_i[G_i], and then goes down [up]. We say that component i is failed at time t if it has been “down” at all time points s ?[t-A.t]: otherwise it is said to be working. Thus, a component is failed if it is down and has been down for the previous A time units. Assuming that all components initially start “up,” let T denote the first time they are all failed, at which point we say the system is failed. We obtain the moment-generating function of T when n = l, for general F and G, thus generalizing previous results which assumed that at least one of these distributions be exponential. In addition, we present a condition under which T is an NBU (new better than used) random variable. Finally we assume that all the up and down distributions F_i and G_i i = l,….n, are exponential, and we obtain an exact expression for E(T) for general n; in addition we obtain bounds for all higher moments of T by showing that T is NBU.     

Optimal scheduling of objects in circulating systems

A “circulating system” is a finite collection of objects, each of which is oscillaling between two states. The prototype system is that of ships on patrcl,each subject to a quasi-regular “duty-service” cycle. There are various restrictions on the time spent in either state by an object and on the number of objects in a state at any one time. Schedules are sought in which the total number in one state is as large and as constant as possible. The maximal average number in one state is calculated, and a necessary and sufficient condition is given for a schedule to achieve it. Procedures are developed for constructing a schedule which achieves the maximal average in the most constant manner.     

Optimal number of minimal repairs before replacement of a system subject to shocks

A system is subject to shocks that arrive according to a nonhomogeneous Poisson process. As shocks occur a system has two types of failures. Type 1 failure (minor failure) is removed by a minimal repair, whereas type 2 failure (catastrophic failure) is removed by replacement. The probability of a type 2 failure is permitted to depend on the number of shocks since the last replacement. A system is replaced at the times of type 2 failure or at the nth type 1 failure, whichever comes first. The optimal policy is to select n* to minimize the expected cost per unit time for an infinite time span. A numerical example is given to illustrate the method. © 1996 John Wiley & Sons, Inc.     

A branch‐and‐cut algorithm for the nonpreemptive swapping problem

In the Swapping Problem (SP), we are given a complete graph, a set of object types, and a vehicle of unit capacity. An initial state specifies the object type currently located at each vertex (at most one type per vertex). A final state describes where these object types must be repositioned. In general, there exist several identical objects for a given object type, yielding multiple possible destinations for each object. The SP consists of finding a shortest vehicle route starting and ending at an arbitrary vertex, in such a way that each object is repositioned in its final state. This article exhibits some structural properties of optimal solutions and proposes a branch‐and‐cut algorithm based on a 0‐1 formulation of the problem. Computational results on random instances containing up to 200 vertices and eight object types are reported. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009     

Optimal refueling sequence for a mixed fleet with limited refuelings

Consider a fleet of vehicles comprised of K₁ identical tankers and K₂ identical nontankers (small aircraft). Tankers are capable of refueling other tankers as well as nontankers. The problem is to find that refueling sequence of the tankers that maximizes the range simultaneously attainable by all K₂ nontankers. A recent paper established that the “unit refueling sequence,” comprised of one tanker refueling at each of K₁ refueling operations, is optimal. The same paper also proffered the following conjecture for the case that the number of refueling operations is constrained to be less than the number of tankers: A nonincreasing refueling sequence is optimal. This article proves the conjecture.     

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     

On the optimal policies of an exponential machine repair problem

We consider an exponential repair model with s machines and one repairman. The machines' failure rates are equal but the repair rate may change from machine to machine. The repairman repairs the failed machines one at a time and in the course of his work he may even interrupt repairing one machine and start another. We compare repair policies and prove an optimality result by means of stochastic order. The proof is based on representing the compared models simultaneously in a special way and comparing then the sample paths of the interesting stochastic processes.     

Customer delays in M/M/c repair systems with spares

A service center to which customers bring failed items for repair is considered. The items are exchangeable in the sense that a customer is ready to take in return for the failed item he brought to the center any good item of the same kind. This exchangeability feature makes it possible for the service center to possess spares. The focus of the article is on customer delay in the system—the time that elapses since the arrival of a customer with a failed item and his departure with a good one—when repaired items are given to waiting customers on a FIFO basis. An algorithm is developed for the computation of the delay distribution when the item repair system operates as an M/M/c queue.     

Evaluation of costs of ordering policies in large machine repair problems

This article examines a version of the machine repair problem where failures may be irreparable. Since the number of machines in the system keeps decreasing, we impose a fixed state-dependent ordering policy of the type often encountered in inventory models. Although the system is Markovian, the number of states becomes very large. The emphasis of the article, therefore, is on deriving computationally tractable formulas for the steady-state probabilities, the long-run average cost per unit time, and the vector of expected discounted costs. When the state space is so large that exact computations may be infeasible, we propose approximations which are relatively quick and simple to compute and which yield very accurate results for the test problems examined.