Maintenance policies when failure distribution of equipment is only partially known

An optimal schedule for checking an equipment subject to failure which can be detected by inspection only, is derived. Increasing failure rate and one percentile specify the otherwise unknown life distribution. Dynamic programming methodology yields the solution which minimizes the maximum expected cost. Numerical examples are presented and compared with models employing differing amounts of knowledge.     

Application of Markov renewal theory and semi-Markov decision processes in maintenance modeling and optimization of multi-unit systems

In this paper, a condition-based maintenance model for a multi-unit production system is proposed and analyzed using Markov renewal theory. The units of the system are subject to gradual deterioration, and the gradual deterioration process of each unit is described by a three-state continuous time homogeneous Markov chain with two working states and a failure state. The production rate of the system is influenced by the deterioration process and the demand is constant. The states of the units are observable through regular inspections and the decision to perform maintenance depends on the number of units in each state. The objective is to obtain the steady-state characteristics and the formula for the long-run average cost for the controlled system. The optimal policy is obtained using a dynamic programming algorithm. The result is validated using a semi-Markov decision process formulation and the policy iteration algorithm. Moreover, an analytical expression is obtained for the calculation of the mean time to initiate maintenance using the first passage time theory.     

求解整数规划问题的一个搜索方法

本文整数规划问题给出一种搜索方法,它类似于求解连续变量优化问题的迭代方法,从一个好的初始可行解出发,寻找一个搜索方向,沿着这个方向求出改进的可行解,然后又开始下一次迭代。此方法简单易行,可以求出问题的最优解或近似最优解,对于整数线性规划问题和整数非线性规划问题的求解都适用,并且容易推广到求解大规校整数线性规划问题。文中附有计算例子,说明方法是有效的。     

Assessment of hazardous-inspection policies

Inspection procedures may at times pose a hazard to the system being monitored. In this article, a simple hazardous-inspection model is considered. The character of the optimal ongoing inspection policy (for inspections subsequent to the first) is reviewed, and the possible forms of the optimal initiation policy are established. Efficient computational procedures are developed for calculating optimal policies. Some discussion is included of the counterintuitive nature of some of the results.     

Resource allocation with lumpy demand: To speed or not to speed?

In the classical EPQ model with continuous and constant demand, holding and setup costs are minimized when the production rate is no larger than the demand rate. However, the situation may change when demand is lumpy. We consider a firm that produces multiple products, each having a unique lumpy demand pattern. The decision involves determining both the lot size for each product and the allocation of resources for production rate improvements among the products. We find that each product's optimal production policy will take on only one of two forms: either continuous production or lot‐for‐lot production. The problem is then formulated as a nonlinear nonsmooth knapsack problem among products determined to be candidates for resource allocation. A heuristic procedure is developed to determine allocation amounts. The procedure decomposes the problem into a mixed integer program and a nonlinear convex resource allocation problem. Numerical tests suggest that the heuristic performs very well on average compared to the optimal solution. Both the model and the heuristic procedure can be extended to allow the company to simultaneously alter both the production rates and the incoming demand lot sizes through quantity discounts. Extensions can also be made to address the case where a single investment increases the production rate of multiple products. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004.     

Optimal inspection under semi-markovian deterioration: Basic results

This article develops a model for determining the optimal inspection schedule for a system which deteriorates according to a semi-Markov process that progresses through three states: good, defective, and bad. A binary test is used, and false positives may occur. A true positive results in an action that reduces the likelihood of entering the bad state, but at most one such corrective action can occur during the lifetime of the system. Costs are associated with each inspection, each false positive, the corrective action, and the entrance into the bad state. Dynamic programming is used to compute the minimum expected cost, which is a function of the age of the system. The optimal inspection schedule is readily derived from this value function. Computational examples are provided. This model is appropriate for medical screening or for a mission where there is only one spare part.     

Optimal capacity in a coordinated supply chain

We consider a supply chain in which a retailer faces a stochastic demand, incurs backorder and inventory holding costs and uses a periodic review system to place orders from a manufacturer. The manufacturer must fill the entire order. The manufacturer incurs costs of overtime and undertime if the order deviates from the planned production capacity. We determine the optimal capacity for the manufacturer in case there is no coordination with the retailer as well as in case there is full coordination with the retailer. When there is no coordination the optimal capacity for the manufacturer is found by solving a newsvendor problem. When there is coordination, we present a dynamic programming formulation and establish that the optimal ordering policy for the retailer is characterized by two parameters. The optimal coordinated capacity for the manufacturer can then be obtained by solving a nonlinear programming problem. We present an efficient exact algorithm and a heuristic algorithm for computing the manufacturer's capacity. We discuss the impact of coordination on the supply chain cost as well as on the manufacturer's capacity. We also identify the situations in which coordination is most beneficial. © 2008 Wiley Periodicals, Inc. Naval Research Logistics, 2008     

A two product dynamic economic lot size production model with either-or production constraints

This paper considers the production of two products with known demands over a finite set of periods. The production and inventory carrying costs for each product are assumed to be concave. We seek the minimum cost production schedule meeting all demands, without backlogging, assuming that at most one of the two products can be produced in any period. The optimization problem is first stated as a nonlinear programming problem, which allows the proof of a result permitting the search for the optimal policy to be restricted to those which produce a product only when its inventory level is zero. A dynamic programming formulation is given and the model is then formulated as a shortest route problem in a specially constructed network.     

Termination policies for a two-state stochastic process

The purpose of this paper is to investigate and optimize policies which can be used to terminate a two-state stochastic process with a random lifetime. Such a policy consists of a schedule of times at which termination attempts should be made. Conditions are given which reduce the difficulty of finding the optimal policy by eliminating constraints and some boundary points from consideration. Finally, a bound for the optimal policy is derived for a case where some restrictions are imposed on the model.     

Optimal scheduling of reader—systems

We consider a reader—writer system consisting of a single server and a fixed number of jobs (or customers) belonging to two classes. Class one jobs are called readers and any number of them can be processed simultaneously. Class two jobs are called writers and they have to be processed one at a time. When a writer is being processed no other writer or readers can be processed. A fixed number of readers and writers are ready for processing at time 0. Their processing times are independent random variables. Each reader and writer has a fixed waiting cost rate. We find optimal scheduling rules that minimize the expected total waiting cost (expected total weighted flowtime). We consider both nonpreemptive and preemptive scheduling. The optimal nonpreemptive schedule is derived by a variation of the usual interchange argument, while the optimal schedule in the preemptive case is given by a Gittins index policy. These index policies continue to be optimal for systems in which new writers enter the system in a Poisson fashion. © 1998 John Wiley & Sons, Inc. Naval Research Logistics 45: 483–495, 1998     

The open shop scheduling problem with a given sequence of jobs on one machine

The paper considers the open shop scheduling problem to minimize the make-span, provided that one of the machines has to process the jobs according to a given sequence. We show that in the preemptive case the problem is polynomially solvable for an arbitrary number of machines. If preemption is not allowed, the problem is NP-hard in the strong sense if the number of machines is variable, and is NP-hard in the ordinary sense in the case of two machines. For the latter case we give a heuristic algorithm that runs in linear time and produces a schedule with the makespan that is at most 5/4 times the optimal value. We also show that the two-machine problem in the nonpreemptive case is solvable in pseudopolynomial time by a dynamic programming algorithm, and that the algorithm can be converted into a fully polynomial approximation scheme. © 1998 John Wiley & Sons, Inc. Naval Research Logistics 45: 705–731, 1998     

Inspection policies and processes for deteriorating systems subject to catastrophic failure

Deteriorating reliability systems that are subject to catastrophic failure are analyzed in order to propose and evaluate some deterministic and stochastic inspection models. The underlying deterioration process is assumed to be an increasing Markov renewal process where the true state of the system can not be determined by simple observations. Instead, some tests can be done in order to detect if the system has positive deterioration or not. The results of the tests, however, are not perfect so that the probability of true and false detections depend on the unobserved state of the system. The system is inspected either deterministically at prespecified points in time, or stochastically at random points in time. Both types of models are considered to present explicit computational expressions for various performance measures like the expected number of inspections with different results and the probability of detection. Some practical applications of the results are also included.     

The discrete max-min problem

The historic max-min problem is examined as a discrete process rather than in its more usual continuous mode. Since the practical application of the max-min model usually involves discrete objects such as ballistic missiles, the discrete formulation of the problem seems quite appropriate. This paper uses an illegal modification to the dynamic programming process to obtain an upper bound to the max-min value. Then a second but legal application of dynamic programming to the minimization part of the problem for a fixed maximizing vector will give a lower bound to the max-min value. Concepts of optimal stopping rules may be applied to indicate when sufficiently near optimal solutions have been obtained.     

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     

Production to order and off‐line inspection when the production process is partially observable

This study combines inspection and lot‐sizing decisions. The issue is whether to INSPECT another unit or PRODUCE a new lot. A unit produced is either conforming or defective. Demand need to be satisfied in full, by conforming units only. The production process may switch from a “good” state to a “bad” state, at constant rate. The proportion of conforming units in the good state is higher than in the bad state. The true state is unobservable and can only be inferred from the quality of units inspected. We thus update, after each inspection, the probability that the unit, next candidate for inspection, was produced while the production process was in the good state. That “good‐state‐probability” is the basis for our decision to INSPECT or PRODUCE. We prove that the optimal policy has a simple form: INSPECT only if the good‐state‐probability exceeds a control limit. We provide a methodology to calculate the optimal lot size and the expected costs associated with INSPECT and PRODUCE. Surprisingly, we find that the control limit, as a function of the demand (and other problem parameters) is not necessarily monotone. Also, counter to intuition, it is possible that the optimal action is PRODUCE, after revealing a conforming unit. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

Optimal control policies for a periodic review inventory system with emergency orders

We describe a periodic review inventory system where emergency orders, which have a shorter supply lead time but are subject to higher ordering cost compared to regular orders, can be placed on a continuous basis. We consider the periodic review system in which the order cycles are relatively long so that they are possibly larger than the supply lead times. Study of such systems is important since they are often found in practice. We assume that the difference between the regular and emergency supply lead times is less than the order-cycle length. We develop a dynamic programming model and derive a stopping rule to end the computation and obtain optimal operation parameters. Computational results are included that support the contention that easily implemented policies can be computed with reasonable effort. © 1998 John Wiley & Sons, Inc. Naval Research Logistics 45: 187–204, 1998     

Dynamic pricing and replenishment: Optimality,bounds, and asymptotics

In many applications, managers face the problem of replenishing and selling products during a finite time horizon. We investigate the problem of making dynamic and joint decisions on product replenishment and selling in order to improve profit. We consider a backlog scenario in which penalty cost (resulting from fulfillment delay) and accommodation cost (resulting from shortage at the end of the selling horizon) are incurred. Based on continuous‐time and discrete‐state dynamic programming, we study the optimal joint decisions and characterize their structural properties. We establish an upper bound for the optimal expected profit and develop a fluid policy by resorting to the deterministic version of the problem (ie, the fluid problem). The fluid policy is shown to be asymptotically optimal for the original stochastic problem when the problem size is sufficiently large. The static nature of the fluid policy and its lack of flexibility in matching supply with demand motivate us to develop a “target‐inventory” heuristic, which is shown, numerically, to be a significant improvement over the fluid policy. Scenarios with discrete feasible sets and lost‐sales are also discussed in this article.     

Scheduling of depalletizing and truck loading operations in a food distribution system

This paper studies a scheduling problem arising in a beef distribution system where pallets of various types of beef products in the warehouse are first depalletized and then individual cases are loaded via conveyors to the trucks which deliver beef products to various customers. Given each customer's demand for each type of beef, the problem is to find a depalletizing and truck loading schedule that fills all the demands at a minimum total cost. We first show that the general problem where there are multiple trucks and each truck covers multiple customers is strongly NP‐hard. Then we propose polynomial‐time algorithms for the case where there are multiple trucks, each covering only one customer, and the case where there is only one truck covering multiple customers. We also develop an optimal dynamic programming algorithm and a heuristic for solving the general problem. By comparing to the optimal solutions generated by the dynamic programming algorithm, the heuristic is shown to be capable of generating near optimal solutions quickly. © 2003 Wiley Periodicals, Inc. Naval Research Logistics, 2003     

Value management of diagnostic equipment with cancelation,no‐show,and emergency patients

Magnetic resonance imaging and other multifunctional diagnostic facilities, which are considered as scarce resources of hospitals, typically provide services to patients with different medical needs. This article examines the admission policies during the appointment management of such facilities. We consider two categories of patients: regular patients who are scheduled in advance through an appointment system and emergency patients with randomly generated demands during the workday that must be served as soon as possible. According to the actual medical needs of patients, regular patients are segmented into multiple classes with different cancelation rates, no‐show probabilities, unit value contributions, and average service times. Management makes admission decisions on whether or not to accept a service request from a regular patient during the booking horizon to improve the overall value that could be generated during the workday. The decisions should be made by considering the cancelation and no‐show behavior of booked patients as well as the emergency patients that would have to be served because any overtime service would lead to higher costs. We studied the optimal admission decision using a continuous‐time discrete‐state dynamic programming model. Identifying an optimal policy for this discrete model is analytically intractable and numerically inefficient because the state is multidimensional and infinite. We propose to study a deterministic counterpart of the problem (i.e., the fluid control problem) and to develop a time‐based fluid policy that is shown to be asymptotically optimal for large‐scale problems. Furthermore, we propose to adopt a mixed fluid policy that is developed based on the information obtained from the fluid control problem. Numerical experiments demonstrate that this improved policy works effectively for small‐scale problems. © 2016 Wiley Periodicals, Inc. Naval Research Logistics 63: 287–304, 2016     

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