Optimal replacement under additive damage and other failure models

A machine or production system is subject to random failure. Upon failure the system is replaced by a new one, and the process repeats. A cost is associated with each replacement, and an additional cost is incurred at each failure in service. Thus, there is an incentive for a controller to attempt to replace before failure occurs. The problem is to find an optimal control strategy that balances the cost of replacement with the cost of failure and results in a minimum total long-run average cost per unit time. We attack this problem under the cumulative damage model for system failure. In this failure model, shocks occur to the system in accordance with a Poisson process. Each shock causes a random amount of damage or wear and these damages accumulate additively. At any given shock, the system fails with a known probability that depends on the total damage accumulated to date. We assume that the cumulative damage is observable by the controller and that his decisions may be based on its current value. Supposing that the shock failure probability is an increasing function of the cumulative damage, we show that an optimal policy is to replace either upon failure or when this damage first exceeds a critical control level, and we give an equation which implicitly defines the optimal control level in terms of the cost and other system parameters. Also treated are some more general models that allow for income lost during repair time and other extensions.     

Optimal maintenance policy for stochastically failing equipment: A diffusion approximation

A system receives shocks at random points of time. Each shock causes a random amount of damage which accumulates over time. The system fails when the accumulated damage exceeds a fixed threshold. Upon failure the system is replaced by a new one. The damage process is controlled by means of a maintenance policy. There are M possible maintenance actions. Given that a maintenance action m is employed, then the cumulative damage decreases at rate r^m. Replacement costs and maintenance costs are considered. The objective is to determine an optimal maintenance policy under the following optimality criteria: (1) long-run average cost; (2) total expected discounted cost over an infinite horizon. For a diffusion approximation, we show that the optimal maintenance expenditure rate is monotonically increasing in the cumulative damage level.     

Replacement models under additive damage

A production system which generates income is subject to random failure. Upon failure, the system is replaced by a new identical one and the replacement cycles are repeated indefinitely. In our breakdown model, shocks occur to the system in a Poisson stream. Each shock causes a random amount of damage, and these damages accumulate additively. The failure time depends on the accumulated damage in the system. The income from the system and the cost associated with a planned replacement depend on the accumulated damage in the system. An additional cost is incurred at each failure in service. We allow a controller to replace the system at any stopping time T before failure time. We will consider the problem of specifying a replacement rule that is optimal under the following criteria: maximum total long-run average net income per unit time, and maximum total long-run expected discounted net income. Our primary goal is to introduce conditions under which an optimal policy is a control limit policy and to investigate how the optimal policy can be obtained. Examples will be presented to illustrate computational procedures.     

A cumulative damage shock model with imperfect preventive maintenance

In this article we consider a cumulative damage shock model under a periodic preventive maintenance (PM) policy. The PM is imperfect in the sense that each PM reduces the damage level by 100(1 – b)%, 0 < b < 1. A system suffers damage due to shocks and fails when the damage level exceeds some threshold. We derive a sufficient condition for the time to failure to have an IFR distribution. We also discuss the associated problem of finding the number of PM's that minimizes the expected cost rate.     

An alternative proof of the IFRA property of some shock models

Let , where A (t)/t is nondecreasing in t, {P(k)^1/k} is nonincreasing. It is known that H(t) = 1 — H (t) is an increasing failure rate on the average (IFRA) distribution. A proof based on the IFRA closure theorem is given. H(t) is the distribution of life for systems undergoing shocks occurring according to a Poisson process where P (k) is the probability that the system survives k shocks. The proof given herein shows there is an underlying connection between such models and monotone systems of independent components that explains the IFRA life distribution occurring in both models.     

Preservation of unimodality under shock models

A number of results pertaining to preservation of aging properties (IFR, IFRA etc.) under various shock models are available in the literature. Our aim in this paper is to examine in the same spirit, the preservation of unimodality under various shock models. For example, it is proved that in a non-homogeneous Poisson shock model if {p_k}_K≥0, the sequence of probabilities with which the device fails on the kth shock, is unimodal then under some suitable conditions on the mean value function Λ (t), the corresponding survival function is also unimodal. The other shock models under which the preservation of unimodality is considered in this paper are pure birth shock model and a more general shock model in which shocks occur according to a general counting process. © 1999 John Wiley & Sons, Inc. Naval Research Logistics 46: 952–957, 1999     

Preventive maintenance and replacement under additive damage

A system deteriorates due to shocks received at random times, each shock causing a random amount of damage which accumulates over time and may result in a system failure. Replacement of a failed system is mandatory, while an operable one may also be replaced. In addition, the shock process causing system deterioration may be controlled by continuous preventive maintenance expenditures. The joint problem of optimal maintenance and replacement is analyzed and it is shown that, under reasonable conditions, optimal maintenance rate is decreasing in the cumulative damage level and that beyond a certain critical level the system should be replaced. Meaningful bounds are established on the optimal policies and an illustrative example is provided.     

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.     

Two novel critical shock models based on Markov renewal processes

In this paper, we investigate systems subject to random shocks that are classified into critical and noncritical categories, and develop two novel critical shock models. Classical extreme shock models and run shock models are special cases of our developed models. The system fails when the total number of critical shocks reaches a predetermined threshold, or when the system stays in an environment that induces critical shocks for a preset threshold time, corresponding to failure mechanisms of the developed two critical shock models respectively. Markov renewal processes are employed to capture the magnitude and interarrival time dependency of environment-induced shocks. Explicit formulas for systems under the two critical shock models are derived, including the reliability function, the mean time to failure and so on. Furthermore, the two critical shock models are extended to the random threshold case and the integrated case where formulas of the reliability indexes of the systems are provided. Finally, a case study of a lithium-ion battery system is conducted to illustrate the proposed models and the obtained results.     

Markovian approximation for manufacturing systems of unreliable machines in tandem

This paper studies production planning of manufacturing systems of unreliable machines in tandem. The manufacturing system considered here produces one type of product. The demand is assumed to be a Poisson process and the processing time for one unit of product in each machine is exponentially distributed. A broken machine is subject to a sequence of repairing processes. The up time and the repairing time in each phase are assumed to be exponentially distributed. We study the manufacturing system by considering each machine as an individual system with stochastic supply and demand. The Markov Modulated Poisson Process (MMPP) is applied to model the process of supply. Numerical examples are given to demonstrate the accuracy of the proposed method. We employ (s, S) policy as production control. Fast algorithms are presented to solve the average running costs of the machine system for a given (s, S) policy and hence the approximated optimal (s, S) policy. © 2001 John Wiley & Sons, Inc. Naval Research Logistics 48: 65–78, 2001     

Stochastic control of queueing systems

Suppose that the state of a queueing system is described by a Markov process { Y_t, t ≥ 0}, and the profit from operating it up to a time t is given by the function f(Y_t). We operate the system up to a time T, where the random variable T is a stopping time for the process Yt. Optimal stochastic control is achieved by choosing the stopping time T that maximizes Ef(Y_T) over a given class of stopping times. In this paper a theory of stochastic control is developed for a single server queue with Poisson arrivals and general service times.     

A compound measure of dependability for systems modeled by continuous-time absorbing Markov processes

The Markov analysis of reliability models frequently involves a partitioning of the state space into two or more subsets, each corresponding to a given degree of functionality of the system. A common partitioning is G ∪ B ∪ {o}, where G (good) and B (bad) stand, respectively, for fully and partially functional sets of system states; o denotes system failure. Visits to B may correspond to, for instance, reparable system downtimes, whereas o will stand for irrecoverable system failure. Let T_G and N_B stand, respectively, for the total time spent in G, and the number of visits to B, until system failure. Both T_G and N_B are familiar system performance measures with well-known cumulative distribution functions. In this article a closed-form expression is established for the probability Pr[T_G <> t, N_B ≤ n], a dependability measure with much intuitive appeal but which hitherto seems not to have been considered in the literature. It is based on a recent result on the joint distribution of sojourn times in subsets of the state space by a Markov process. The formula is explored numerically by the example of a power transmission reliability model. © 1996 John Wiley & Sons, Inc.     

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     

A note on the optimal replacement time of damaged devices

Abdel Hameed and Shimi [1] in a recent paper considered a shock model with additive damage. This note generalizes the work of Abdel Hameed and Shimi by showing that the a-priori restriction to replacement at a shock time made in [1] is unnecessary.     

A test for the hypothesis that two extreme-value scale parameters are equal

A statistic is determined for testing the hypothesis of equality for scale parameters from two populations, each of which has the first asymptotic distribution of smallest (extreme) values. The probability distribution is derived for this statistic, and critical values are determined and given in tabular form for a one-sided or two-sided alternative, for censored samples of size n₁ and n₂, n₁ = 2, 3, …. 6, n₂ = 2, 3, …. 6. The power function of the test for certain alternatives is also calculated and listed in each case considered.     

Optimal selection of the t best of a sequence with sampling cost

This article deals with the problem of selecting the t best of n independent and identically distributed random variables which are observed sequentially with sampling cost c per unit. Assume that a decision for acceptance or rejection must be made after each sampling and that the reward for each observation with value x is given by px - c, where p is 1 if the observation is accepted, or 0 otherwise. The optimal decision procedure (strategy) for maximizing the total expected reward is obtained. The critical numbers which are necessary to carry out the optimal decision procedure is presented by two recursive equations. The limit values of the critical numbers and the expected sample size are also studied.     

Real-time task scheduling with overheads considered

n periodic tasks are to be processed by a single machine, where each task i has a maximum request rate or periodicity F_i, a processing time E_i, a deadline D_i, relative to each request of task i, a task-request interrupt overhead I_i, and a task-independent scheduling overhead S. Two scheduling strategies are considered for sequencing the execution of an arbitrary arrangement of task requests in time: the preemptive and the nonpreemptive earliest-deadline algorithms. Necessary and sufficient conditions are derived for establishing whether a given set of tasks can be scheduled by each scheduling strategy. The conditions are given in the form of limited simulations of a small number of well-defined task-request arrangements. If all simulations succeed, the schedule is feasible for the given set of tasks. If any simulation fails, the schedule is infeasible. While interrupt handling and scheduling overheads can be handled by such simulations, context switching overhead resulting from preemption cannot. A counterexample illustrates how the simulations fail to uncover unschedulable task sets when context switching overhead is considered.     

The applicability of acceptance sampling with respect to process stability and control

This article examines the applicability of acceptance sampling and the effectiveness of Deming's kp rule in relation to the degree of process stability achieved through statistical process control techniques. A discrete-event simulation model is used to characterize the correlation between the number of defective units in a randomly drawn sample versus in the remainder of a lot, in response to a number of system and control chart parameters. The model reveals that such correlation is typically present when special causes of variation affect the production process from time to time, even though the process is tightly monitored through statistical process control. Comparison of these results to an analogous mixed binomial scenario reveals that the mixed binomial model overstates the correlation in question if the state of the process is not necessarily constant during lot production. A generalization of the kp analysis is presented that incorporates the possibility of dependence between a sample and the unsampled portion of the lot. This analysis demonstrates that acceptance sampling is generally ineffective for lots generated by a process subject to statistical process control, despite the fact that the number of defectives in the sample and in the remainder of the lot are not strictly independent. © 1994 John Wiley & Sons, Inc.     

A two-echelon multi-station inventory model for navy applications

The two inventory echelons under consideration are the depot, D, and k tender ships E₁, …, E_k. The tender ships supply the demand for certain parts of operational boats (the customers). The statistical model assumes that the total monthly demands at the k tenders are stationary independent Poisson random variables, with unknown means λ₁, …, λ_k. The stock levels on the tenders, at the heginning of each month, can be adjusted either by ordering more units from the depot, or by shipping bach to the depot an excess stock. There is no traffic of stock between tenders which is not via the depot. The lead time from the depot to the tenders is at most 1 month. The lead time for orders of the depot from the manufacturer is L months. The loss function due to erroneous decision js comprised of linear functions of the extra monthly stocks, and linear functions of shortages at the tenders and at the depot over the N months. A Bayes sequential decision process is set up for the optimal adjustment levels and orders of the two echelons. The Dynamic Programming recursive functions are given for a planning horizon of N months.