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     

Bounding the optimal burn‐in time for a system with two types of failure

Burn‐in is a widely used method to improve the quality of products or systems after they have been produced. In this paper, we consider the problem of determining bounds to the optimal burn‐in time and optimal replacement policy maximizing the steady state availability of a repairable system. It is assumed that two types of system failures may occur: One is Type I failure (minor failure), which can be removed by a minimal repair, and the other is Type II failure (catastrophic failure), which can be removed only by a complete repair. Assuming that the underlying lifetime distribution of the system has a bathtub‐shaped failure rate function, upper and lower bounds for the optimal burn‐in time are provided. Furthermore, some other applications of optimal burn‐in are also considered. © 2004 Wiley Periodicals, Inc. Naval Research Logistics, 2004     

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 production and maintenance policy for imperfect production systems

A joint optimization of the production run length and preventive maintenance (PM) policy is studied for a deteriorating production system where the in‐control period follows a general probability distribution with non‐decreasing failure rate. In the literature, the sufficient conditions for the optimality of the equal‐interval PM schedule is explored to derive an optimal production run length and an optimal number of PM actions. Nevertheless, an exhaustive search may arise. In this study, based on the assumption that the conditions for the optimality of the equal‐interval PM schedule hold, we derive some structural properties for the optimal production/PM policy, which increases the efficiency of the solution procedure. These analyses have implications for the practical application of the production/PM model to be more available in practice. A numerical example of gamma shift distribution with non‐decreasing failure rates is used to illustrate the solution procedure, leading to some insight into the management process. © 2005 Wiley Periodicals, Inc. Naval Research Logistics, 2006     

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).     

Spares stocking policies for repairable items with dependent repair times

This paper analyzes the problem of determining desirable spares inventory levels for repairable items with dependent repair times. The problem is important for repairable products such as aircraft engines which can have very large investment in spares inventory levels. While existing models can be used to determine optimal inventory spares levels when repair times are independent, the practical considerations of limited repair shop capacity and prioritized shop dispatching rules combine to make repair times not independent of one another. In this research a simulation model of a limited capacity repair facility with prioritized scheduling is used to explore a variety of heuristic approaches to the spares stocking decision. The heuristics are also compared with use of a model requiring independent repair times (even though that assumption is not valid here). The results show that even when repair time dependencies are present, the performance of a model which assumes independent repair times is quite good.     

A methodology for studying the dynamics of extended logistic systems

An extended logistic system is a well-defined configuration of equipment, modules, inventories, and repair and replacement facilities modeling a complex, repairable system with on-going repair. The design of such systems has been based largely on the static tools of inventory theory and reliability theory, i.e., on steady-state distributions and on associated means and variances. Such static tools suppress the scale of real lime and ignore system persistence time in up-states and persistence time in down-states. A reasonably simple dynamic methodology is presented, focusing on system failure time as a more meaningful objective function for system-design tradeoff studies. In the presence of good reliability, it is shown that different candidates for system failure time effectively merge to yield an unambiguous, single system failure time. Examples illustrating the importance of dynamic information for system design are given.     

Optimal (τ, T) opportunistic maintenance of a k‐out‐of‐n:G system with imperfect PM and partial failure

The opportunistic maintenance of a k‐out‐of‐n:G system with imperfect preventive maintenance (PM) is studied in this paper, where partial failure is allowed. In many applications, the optimal maintenance actions for one component often depend on the states of the other components and system reliability requirements. Two new (τ, T) opportunistic maintenance models with the consideration of reliability requirements are proposed. In these two models, only minimal repairs are performed on failed components before time τ and the corrective maintenance (CM) of all failed components are combined with PM of all functioning but deteriorated components after τ; if the system survives to time T without perfect maintenance, it will be subject to PM at time T. Considering maintenance time, asymptotic system cost rate and availability are derived. The results obtained generalize and unify some previous research in this area. Application to aircraft engine maintenance is presented. © 2000 John Wiley & Sons;, Inc. Naval Research Logistics 47: 223–239, 2000     

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     

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.     

Maintaining systems with heterogeneous spare parts

We consider the problem of optimally maintaining a stochastically degrading, single‐unit system using heterogeneous spares of varying quality. The system's failures are unannounced; therefore, it is inspected periodically to determine its status (functioning or failed). The system continues in operation until it is either preventively or correctively maintained. The available maintenance options include perfect repair, which restores the system to an as‐good‐as‐new condition, and replacement with a randomly selected unit from the supply of heterogeneous spares. The objective is to minimize the total expected discounted maintenance costs over an infinite time horizon. We formulate the problem using a mixed observability Markov decision process (MOMDP) model in which the system's age is observable but its quality must be inferred. We show, under suitable conditions, the monotonicity of the optimal value function in the belief about the system quality and establish conditions under which finite preventive maintenance thresholds exist. A detailed computational study reveals that the optimal policy encourages exploration when the system's quality is uncertain; the policy is more exploitive when the quality is highly certain. The study also demonstrates that substantial cost savings are achieved by utilizing our MOMDP‐based method as compared to more naïve methods of accounting for heterogeneous spares.     

A survey of preventive maintenance models for stochastically deteriorating single-unit systems

A survey of the research done on preventive maintenance is presented. The scope of the present survey is on the research published after the 1976 paper by Pierskalla and Voelker [98]. This article includes optimization models for repair, replacement, and inspection of systems subject to stochastic deterioration. A classification scheme is used that categorizes recent research into inspection models, minimal repair models, shock models, or miscellaneous replacement models.     

On the availability of R out of N repairable systems

An R out of N repairable system consisting of N components and operates if at least R components are functioning. Repairable means that failed components are repaired, and upon repair completion they are as good as new. We derive formulas for the expected up‐time, expected down‐time, and the availability of the system, using Markov renewal processes. We assume that either the repair times of the components are generally distributed and the components' lifetimes are exponential or vice versa. The analysis is done for systems with either cold or warm stand‐by. Numerical examples are given for several life time and repair time distributions. © 2002 Wiley Periodicals, Inc. Naval Research Logistics 49: 483–498, 2002; Published online in Wiley InterScience (www.interscience.wiley.com). DOI 10.1002/nav.10025     

威布尔过程模型在机械系统可靠性中的应用

为了研究复杂可修系统的规律,应用威布尔过程模型,得出这样结果,即提出一种定量描述预防性维修质量的方法,并对MTBF进行了分析。可以这样认为,模型参数在实际工作中有很广泛的应用。     

Multiechelon repairable-item provisioning in a time-varying environment using the randomization technique

Multiechelon repairable-item provisioning systems are considered under a time-varying environment. Such conditions could arise, for example, in a military context where a shift from peacetime operation to wartime operation takes place; or, in a civilian setting where a public transit system decides to increase its hours of operation or frequency of service. Exact Markovian models, incorporating a finite population of repairable components and limited repair capacity (nonample service), are treated, with transient solutions obtained using the randomization technique. The exact models are compared with the approximate Dyna-METRIC model which assumes an infinite population of components and ample repair capacity.     

The optimal burn-in testing of repairable equipment

The subject of this paper is the utilization of the “infant mortality” or decreasing failure rate effect to improve the reliability of repairable devices. Decreasing failure rate implies the possibility that devices which exhibit it can be improved by “burn-in testing” of each unit. Such a test serves to accumulate operating time while shielded from the full costs and consequences of failure. A general formulation of the burn-in test decision for repairable devices is presented and some special cases are solved. A class of models, indexed by the degree of partial replacement present in the repair process, is considered and numerical results for the optimal policy are given for several members of that class. A comparison of those results reveals the profitability of testing increases with the complexity of the repairable device.     

Optimal allocation of minimal repairs in parallel and series systems

In reliability engineering, the concept of minimal repair describes that the repair brings the failed unit (eg, system or component) to the situation which is same as it was just before the failure. With the help of the well‐known Gamma‐Poisson relationship, this paper investigates optimal allocation strategies of minimal repairs for parallel and series systems through implementing stochastic comparisons of various allocation policies in terms of the hazard rate, the reversed hazard rate, and the likelihood ratio orderings. Numerical examples are presented to illustrate these findings as well. These results not only strengthen and generalize some known ones in the seminal work of Shaked and Shanthikumar, but also solve the open problems proposed by Chahkandi et al.'s study and Arriaza et al.'s study.     

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     

Transient analysis of multiple-unit reliability systems

A general Markovian model representing several multiple-unit redundant repairable systems is proposed and its transient behavior is studied. Specifically, for multiple-unit reliability system the reliability and availability functions are derived in an explicit form for the transient case. The stationary availability and mean time to system failure are deduced from the main results as special cases.     

Probabilistic models of decreasing failure rate processes

The “infant mortality” effect observed in the statistical treatment of reliability consists of a decreasing with age of the conditional probability of equipment failure (failure rate). One widely applicable explanatory hypothesis is that of population heterogeneity. This is developed here as a basis for several specific models of decreasing failure rate processes. Since, in the case of repairable devices, decreasing failure rate is often observed after the occurrence of failure and repair, consideration is extended to include repair in an explicit way. This union of failure and repair models is a fruitful one in view of the interaction between the two processes and gives a complete picture of the life of the device in terms of a stochastic process, usually with non-independent interfailure times. Four models, of particular significance due to their plausibility, mathematical tractability, and frugality of parameterization, are presented.