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.     

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.     

Optimal replacement for fault-tolerant systems

We consider the optimal replacement problem for a fault tolerant system comprised of N components. The components are distingushable, and the state of the system is given by knowing exactly which components are operationl and which have failed. The individual component failure rates depend on the state of the entire system. We assume that the rate at which the system produces income decreases as the system deteriorates and the system replacement cost rises. Individual components cannot be replaced. We give a greedy-type algorithm that produces the replacement policy that maximizes the long-run net system income per unit time.     

Optimal replacement policies for multistate deteriorating systems

We consider state-age-dependent replacement policies for a multistate deteriorating system. We assume that operating cost rates and replacement costs are both functions of the underlying states. Replacement times and sojourn times in different states are all state-dependent random variables. The optimization criterion is to minimize the expected long-run cost rate. A policy-improvement algorithm to derive the optimal policy is presented. We show that under reasonable assumptions, the optimal replacement policies have monotonic properties. In particular, when the failure-rate functions are nonincreasing, or when all the replacement costs and the expected replacement times are independent of state, we show that the optimal policies are only state dependent. Examples are given to illustrate the structure of the optimal policies in the special case when the sojourntime distributions are Weibull. © 1994 John Wiley & Sons, Inc.     

Optimal replacement rules based on different information levels

We consider the following replacement model in reliability theory. A technical system with random lifetime is replaced upon failure. Preventive replacements can be carried out before failure. The time for such a replacement depends on the observation of a random state parameter and is therefore in general a random time. Different costs for preventive and failure replacements are introduced which may depend on the age of the working system. The optimization criterion followed here to find an optimal replacement time is to minimize the total expected discounted costs. The optimal replacement policy depends on the observation of the state of the system. Results of the theory of stochastic processes are used to obtain the optimal strategy for different information levels. Several examples based on a two-component parallel system with possibly dependent component lifetimes show how the optimal replacement policy depends on the different information levels and on the degree of dependence of the components. © 1992 John Wiley & Sons, Inc.     

Equipment replacement under technological change

For infinite-horizon replacement economy problems it is common practice to truncate the problem at some finite horizon. We develop bounds on the error due to such a truncation. These bounds differ from previous results in that they include both revenues and costs. Bounds are illustrated through a numerical example from a real case in vehicle replacement. © 1994 John Wiley & Sons, Inc.     

Optimal block replacement policies with multiple choice at failure

In this article we consider block replacement policies where the operating item is replaced by a new one at times kT, k = 1, 2, …, independently of its failure history. At failure the item is either replaced by a new or a used one or remains inactive until the next planned replacement. The mathematical model is defined and general analytical results are obtained. Computations are carried out for the case where the underlying life distribution is gamma or Weibull.     

Optimal investment,pricing and replacement of computer resources

The problem of multiple-resource capacity planning under an infinite time horizon is analyzed using a nonlinear programming model. The analysis generalizes to the long term the short-run pricing model for computer networks developed in Kriebel and Mikhail [5]. The environment assumes heterogeneous resource capacities by age (vingate), which service a heterogeneous and relatively captive market of users with known demand functions in each time period. Total variable operating costs are given by a continuous psuedoconcave function of system load, capacity, and resource age. Optimal investment, pricing, and replacement decision rules are derived in the presence of economies of scale and exogenous technological progress. Myopic properties of the decision rules which define natural (finite) planning subhorizons are discussed.     

Optimal replacement policies with two or more loaded sliding standbys

This article defines optimal replacement policies for identical components performing different functions in a given system, when more than one spare part is available. The problem is first formulated for two components and any number of spare parts and the optimal replacement time y(x) at time x is found to have a certain form. Sufficient conditions are then provided for y(x) to be a constant y* for x > y*, and y(x) = x for x > y* (single-critical-number policy). Under the assumption that the optimal policies are of the single-critical-number type, the results are extended to the n-component case, and a theorem is provided that reduces the required number of critical numbers. Finally, the theory is applied to the case of the exponential and uniform failure laws, in which single-critical-number policies are optimal, and to another failure law in which they are not.     

Optimal replacement of parts having observable correlated stages of deterioration

A single component system is assumed to progress through a finite number of increasingly bad levels of deterioration. The system with level i (0 ≤ i ≤ n) starts in state 0 when new, and is definitely replaced upon reaching the worthless state n. It is assumed that the transition times are directly monitored and the admissible class of strategies allows substitution of a new component only at such transition times. The durations in various deterioration levels are dependent random variables with exponential marginal distributions and a particularly convenient joint distribution. Strategies are chosen to maximize the average rewards per unit time. For some reward functions (with the reward rate depending on the state and the duration in this state) the knowledge of previous state duration provides useful information about the rate of deterioration.     

Timing replacement decisions under discontinuous technological change

We consider the problem of deciding whether to keep a piece of equipment or replace it with a more advanced technology in an environment of technological change. Our model assumes that the costs associated with the presently available technology and future technologies are known, but that the appearance times of future technologies are uncertain. We develop a procedure for computing the optimal keep-or-replace decision that iteratively incorporates a technological forecast. For a certain class of situations, we show that our approach requires the minimum possible amount of forecasted data.     

Optimal policy of continuous and discrete replacement with minimal repair at failure

This article considers combined continuous and discrete replacement with minimal repair at failure, in which a unit is replaced at time T or at number N of uses. Both optimal time T* and number N* to minimize the expected cost rate are discussed. They are found by unique solutions of equations when the hazard rates are monotonously increasing. A numerical example is given.     

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.     

Distributions of manufacturer's and user's replacement costs under warranty

We derive and compute time-dependent distributions of replacement costs under warranty over the product life cycle, both for the manufacturer and the user, under conditional pro-rata and nonrenewing free-replacement warranty policies. For pro-rata warranties, the analysis is based on the joint distribution of the number of replacements and the user's cost over time. For free-replacement warranties, distribution of the user's cost follows from the observation that replacement points outside warranty periods form a renewal process. This property is also exploited to determine the distribution of the manufacturer's cost. We apply our findings to measure the impact of product conformance quality on warranty cost distributions and find that manufacturer's cost measures are more sensitive to changes in quality than user's cost measures. © 1995 John Wiley & Sons, Inc.     

Optimal maintenance and replacement policy for a deteriorating system with increased mean downtime

The problem of imperfect preventive maintenance (pm) and replacement schedule for a system which works below a specified failure rate is studied. For a given planning period, the optimal schedule for replacements to minimize the total cost is obtained. This article presents a branching algorithm with effective dominance rules to obtain the optimal schedule. Numerical illustration and computational experience are also presented.     

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.     

Optimal control for multi-servers queueing systems under periodic review

This paper deals with the problem of finding the optimal dynamic operating policy for an M/M/S queue. The system is observed periodically, and at the beginning of each period the system controller selects the number of service units to be kept open during that period. The optimality criterion used is the total discounted cost over a finite horizon.     

Optimal design of accelerated life tests under periodic inspection

For the exponentially distributed lifetimes, optimal accelerated life test plans are determined under the assumptions of periodic inspection and Type I censoring. Computational results indicate that for the range of parameter values considered the asymptotic variance of the estimated mean or pth quantile at the use stress is not sensitive to the number of inspections at overstress levels. Senstivity analyses are also conducted to see how senstive the asymptotic variance of the estimated mean is with respect to the uncertainties involved in the guessed failure probabilities at the use and high stress levels. Computational results show that moderate deviations (several tens of percents) of the guessed failure probabilities from their true values are fairly tolerable in terms of the relative amount of increase in the asymptotic variance of the estimated mean. Procedures for selecting a sample size and for determining whether or not to conduct an accelerated life test are also discussed.     

Solution algorithms for the parallel replacement problem under economy of scale

We consider the parallel replacement problem in which machine investment costs exhibit economy of scale which is modeled through associating both fixed and variable costs with machine investment costs. Both finite- and infinite-horizon cases are investigated. Under the three assumptions made in the literature on the problem parameters, we show that the finite-horizon problem with time-varying parameters is equivalent to a shortest path problem and hence can be solved very efficiently, and give a very simple and fast algorithm for the infinite-horizon problem with time-invariant parameters. For the general finite-horizon problem without any assumption on the problem parameters, we formulate it as a zero-one integer program and propose an algorithm for solving it exactly based on Benders' decomposition. Computational results show that this solution algorithm is efficient, i.e., it is capable of solving large scale problems within a reasonable cpu time, and robust, i.e., the number of iterations needed to solve a problem does not increase quickly with the problem size. © 1998 John Wiley & Sons, Inc. Naval Research Logistics 45: 279–295, 1998     

工龄更换策略下的备件库存决策研究

针对单部件系统工龄更换策略下备件需求的特点,建立了工龄更换策略与备件库存控制的联合优化模型。该模型通过分析一个订购期内工龄更换间隔期T及备件最大库存水平S对系统寿命分布的影响,建立了工龄更换间隔期、订购间隔期及最大库存水平与单位时间总费用（包括维修费用和库存费用）的关系,然后以单位时间总费用最小为目标,优化工龄更换间隔期T、订购间隔期t0及最大库存水平S。最后,基于案例,运用Matlab对模型进行数值计算,结果表明模型能有效地降低单位时间的总费用。