Some distributions arising as a consequence of errors in inspection

In this article, the authors survey and consolidate their investigations during the years 1980-1983 dealing with consequences of errors in inspection sampling models. Some indication of the current and future research is given.     

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.     

军民融合条件下新型军械装备保修模式研究

针对如何引入承制方优质技术力量支援部队维修保障能力建设这一问题,分析我军现役军械装备维修保障力量、保障模式存在的不足和地方装备维修保障力量的能力特点,明确承制方在军民融合条件下装备维修保障力量中的重要地位.在借鉴国外研究成果的基础上,深入分析和系统设计了我军军械装备的保修模式.结合部队巡检机制,建立了一维免费-按比例收费组合保修的费效模型来验证采购合同中保修条款的合理性.最后进行了案例分析,证明了模型的有效性和实用性.     

A survey of maintenance models: The control and surveillance of deteriorating systems

The literature on maintenance models is surveyed. The focus is on work appearing since the 1965 survey, “Maintenance Policies for Stochastically Failing Equipment: A Survey” by John McCall and the 1965 book, The Mathematical Theory of Reliability, by Richard Barlow and Frank Proschan. The survey includes models which involve an optimal decision to procure, inspect, and repair and/or replace a unit subject to deterioration in service.     

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     

Minimax inspection strategies for single unit systems

A model for proper scheduling of inspections is considered, if system failures can be detected only by checking. Two cases are analyzed: replacement and no replacement of a failed system. On condition that no or only partial information on the lifetime distribution of the system is available, minimax inspection strategies are obtained with respect to cost criterions.     

Machine maintenance with workload considerations

Machine maintenance is modeled in the setting of a single‐server queue. Machine deterioration corresponds to slower service rates and failure. This leads to higher congestion and an increase in customer holding costs. The decision‐maker decides when to perform maintenance, which may be done pre‐emptively; before catastrophic failures. Similar to classic maintenance control models, the information available to the decision‐maker includes the state of the server. Unlike classic models, the information also includes the number of customers in queue. Considered are both a repair model and a replacement model. In the repair model, with random replacement times, fixed costs are assumed to be constant in the server state. In the replacement model, both constant and variable fixed costs are considered. It is shown in general that the optimal maintenance policies have switching curve structure that is monotone in the server state. However, the switching curve policies for the repair model are not always monotone in the number of customers in the queue. Numerical examples and two heuristics are also presented. © 2007 Wiley Periodicals, Inc. Naval Research Logistics, 2007     

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).     

An informal survey of multi-echelon inventory theory

Contained herein is an informal nonmathematical survey of research in multi-echelon inventory theory covering published results through 1971. An introductory section defines the term, “multi-echelon,” and establishes the kinds of problems involving multi-echelon considerations. Subsequent sections provide surveys of research on deterministic and stochastic multi-echelon inventory control problems, allocation models, and multi-echelon planning and evaluation models. A final section discusses the present state of the art and suggests directions for future research. A bibliography of papers concerning multi-echelon inventory theory and applications is included.     

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     

Stepwise inspection in Bayesian multiattribute acceptance sampling

Bayesian models for multiattribute acceptance sampling have been developed under the assumption that sampling inspection is carried to completion. A Bayesian multiattribute model for stepwise sampling inspection is proposed, whereby sampling inspection is terminated as soon as the disposition of the inspection lot is determined. An iterative solution procedure is developed for obtaining optimal or near-optimal multiattribute acceptance sampling plans under stepwise sampling inspection. The effect of stepwise sampling inspection on the characteristics of an optimal sampling plan is investigated. It is shown that stepwise sampling inspection achieves a sampling plan with lower total expected cost than complete sampling inspection. In addition, it is shown that the sequence of attributes in a stepwise sampling inspection substantially affects the sampling plan and resultant expected cost. The proposed methodology is used to evaluate various heuristics which may be used to determine the sequence of attributes in a stepwise inspection procedure.     

A general age replacement model with minimal repair

A general age replacement is introduced which incorporates minimal repair, planned and unplanned replacements, and costs which depend on time. Finite and infinite horizon results are obtained. Various special cases are considered. Furthermore, a shock model with general cost structure is considered.     

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.     

MAD: Mathematical analysis of downtime

The MAD model presents a mathematic treatment of the relationship between aircraft reliability and maintainability, system manning and inspection policies, scheduling and sortie length, and aircraft downtime. Log normal distributions are postulated for subsystem repair times and simultaneous repair of malfunctions is assumed. The aircraft downtime for maintenance is computed with the distribution of the largest of k log normal distributions. Waiting time for maintenance men is calculated either by using a multiple-channel queuing model or by generating the distribution of the number of maintenance men required and comparing this to the number of men available to determine the probability of waiting at each inspection.     

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     

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.     

基于状态的检查与修理综合决策模型

分析了单部件系统退化过程的特点,建立了基于状态的检查与修理决策模型。该模型根据系统的当前状态来决定检查与修理,通过分析计算系统在一个更新周期内平均检查次数、预防性维修及修复性故障的概率,建立维修费用与检查问隔及预防性维修阈值的关系,以平均维修费用最小为目标,优化检查间隔及预防性维修阈值。最后运用Matlab对模型进行数值计算,结果表明,模型能有效地降低维修费用。     

Economic design of sampling plans with multi-decision alternatives

For situations where there are several markets with different profit-cost structures, economic attributes sampling plans are developed for determining the market to ship the lot to. Two sampling plans are considered; the fixed-size sampling plan with several levels of acceptance numbers, and the inverse sampling plan with several levels of sample sizes. Linear profit models are constructed which involve four profit/cost components; profit from a conforming item, inspection cost, replacement cost, and cost from an accepted nonconforming item. For fixed-size and inverse sampling plans, methods of finding optimal sampling plans are presented and examples with beta-binomial prior distributions are given.     

Hybrid minimal repair and age replacement maintenance policies,with nonnegligible repair times

A system undergoes minimal repair during [0, T] with a failure replacement on first failure during [T, a], or a planned replacement if the system is still functioning at elapsed time a. Repairs and replacements are not necessarily instantaneous. An expression is obtained for the asymptotic expected cost rate, and sufficient conditions are obtained for the optimum T* > 0. Several special cases are considered. A numerical investigation for a Weibull distributed time to first failure compares this elapsed-time policy with replacement on failure only, and also a policy based on system operating time or age. It is found that in many cases the elapsed-time-based policy is only marginally worse than one based on system age, and may therefore be preferred in view of its administrative convenience. © 1994 John Wiley & Sons, Inc.     

Quality control chart design under Jidoka

We consider design of control charts in the presence of machine stoppages that are exogenously imposed (as under jidoka practices). Each stoppage creates an opportunity for inspection/repair at reduced cost. We first model a single machine facing opportunities arriving according to a Poisson process, develop the expressions for its operating characteristics and construct the optimization problem for economic design of a control chart. We, then, consider the multiple machine setting where individual machine stoppages may create inspection/repair opportunities for other machines. We develop exact expressions for the cases when all machines are either opportunity‐takers or not. On the basis of an approximation for the all‐taker case, we then propose an approximate model for the mixed case. In a numerical study, we examine the opportunity taking behavior of machines in both single and multiple machine settings and the impact of such practices on the design of an X – Q C chart. Our findings indicate that incorporating inspection/repair opportunities into QC chart design may provide considerable cost savings. © 2009 Wiley Periodicals, Inc. Naval Research Logistics 2009