Cost analysis of a two dissimilar-unit cold standby redundant system subject to inspection and two types of repair

This paper deals with the cost analysis of a two dissimilar-unit cold standby redundant system subject to inspection and two types of repair where each unit of the system has two modes, normal and failed. It is assumed that the failure, repair, replacement and inspection times are stochastically independent random variables each having an arbitrary distribution. The cold standby unit replaces the failed operative unit after a random amount of time. An inspection is required to decide whether it needs type I (minor repair) or type 2 (major repair). In this system the repairman is not always available with the system, but is called whenever the operative unit fails. The system is analysed by the semi-Markov process technique. Some reliability measures of interest to system designers as well as operations managers have been obtained. Pointwise availability, steady-state availability, busy period by a server and the expected cost per unit time of the system are obtained. Certain important results have been derived as particular cases.     

An optimal inspection policy for a storage system with high reliability

A system such as missiles and spare parts of aircrafts has to perform a normal operation at any time when it is used. However, a system is in storage for a long time from the transportation to the usage and its reliability goes down with time. Such a system should be inspected and maintained at periodic times to hold a higher reliability than a prespecified value q. This paper suggests a periodic inspection of a storage system with two kinds of units where unit 1 is inspected and maintained at each inspection, however, unit 2 is not done. The system is replaced at detection of failure or at time when the reliability is below q. The total expected cost until replacement is derived and an optimal inspection time which minimizes it is discussed. Numerical examples are given when failure time distributions are exponential and Weibull ones.     

Optimal number of major failures before replacement

When the repair cost of a failed system is random, it is no longer meaningful to expend more than the replacement cost on a catastrophic failure. This paper presents a mathematical model that uses two cost limits to combine and extend the replacement models based on minor-failure number[8] and constant repair cost limit[5] for general time-to-failure distributions. When the failed system requires repair, it is first inspected and the repair cost is estimated. Minimal repair is only then undertaken if the estimated cost is less than the minor repair-cost limit; or if the estimated cost is less than the replacement cost and the predetermined major-failure number is not reached. An example with a Weibull time-to-failure distribution and a negative exponential distribution of estimated repair cost is given to illustrate the computational results.     

An age replacement policy with minimal repair and general random repair cost

An age replacement policy is introduced which incorporates minimal repair, replacement, and general random repair costs. If an operating unit fails at age y<T, it is either replaced by a new unit with probability p(y) at a cost c₀, or it undergoes minimal repair with probability q(y) = 1−p(y). Otherwise, a unit is replaced when it fails for the first time after age T. The cost of the i-th minimal repair of an unit at age y depends on the random part C(y) and the deterministic part c_i(y). The aim of the paper is to find the optimal T which minimizes the long run expected cost per unit time of the policy. Various special cases are considered.     

Stochastic analysis of a two unit cold standby system with preparation time for repair

This paper deals with the cost-benefit analysis of a two unit cold standby system in which the cold standby unit replaces the failed operative unit after a random amount of time. Inspection is required to decide whether it needs type I or type II repair. Failure, repair, replacement and inspection time distributions are arbitrarily distributed. A repair man is not always available with the system, but is called for repair whenever the operative unit fails.     

Cost-benefit analysis of a single server three-unit redundant system with inspection, delayed replacement and two types of repair

This paper deals with a redundant system with two types of spare units—a warm standby unit for instantaneous replacement at the time of failure of the active unit and a cold standby (stock) unit which can be replaced after a random amount of time. The type of the failure of operative or warm standby unit is detected by inspection only. The service facility plays the triple role of replacement, inspection and repair of a unit. Failure time distributions of operative and warm standby units are negative exponential whereas the distributions of replacement time, inspection time and repair times are arbitrary. The system has been studied by using regenerative points.     

A maintenance strategy for systems subjected to deteriorationgoverned by random shocks

The authors examine the time-stationary availability of maintained systems that deteriorate according to a random-shock process. System failures are not self-announcing; hence, failures must be detected via inspection. The approach considers randomly occurring shocks that cumulatively damage the system; shock magnitudes are taken as random. The authors develop an expression for computing system availability when inspections follow a renewal process. This expression leads to a proved proposition showing that, for any specified mean inspection rate, system availability is maximized by choosing deterministic inter-inspection times     

Optimal maintenance-policies for deteriorating systems undervarious maintenance strategies

This paper presents algorithms for deriving optimal maintenance policies to minimize the mean long-run cost-rate for continuous-time Markov deteriorating systems. The degree of deterioration (except failure) of the system is known only through inspection. The time durations of inspection and replacement are nonnegligible. The costs are for inspection, replacement, operation, and downtime (idle). In particular, the replacement time, replacement cost, and operating cost-rate increase as the system deteriorates. Five maintenance strategies are considered-failure replacement, age replacement, sequential inspection, periodic inspection, and continuous inspection. Iterative algorithms are developed to derive the optimal maintenance policy and the corresponding cost rate for each strategy. Under sufficient conditions, structural optimal policies are obtained     

Periodic replacement with minimal repair at failure and general random repair cost for a multi-unit system

A policy of periodic replacement with minimal repair at failure is considered for the multi-unit system which have the specific multivariate distribution. Under such a policy an operating system is completely replaced whenever it reaches age T (T > 0) at a cost c₀ while minimal repair is performed at any intervening component failures. The cost of the j-th minimal repair to the component which fails at age y is g(C(y),c_j(y)), where C(y) is the age-dependent random part, c_j(y) is the deterministic part which depends on the age and the number of the minimal repair to the component, and g is an positive nondecreasing continuous function. 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 component. Necessary and sufficient conditions for the existence of an optimal replacement interval are exhibited.     

Cost limit replacement policy under minimal repair

This paper presents a policy for either repairing or replacing a system that has failed. When a system requires repair, it is first inspected and the repair cost is estimated. Repair is only then undertaken if the estimated cost is less than the “repair cost limit”. However, the repair cannot return the system to “as new” condition but instead returns it to the average condition for a working system of its age. Examples include complex systems where the repair or replacement of one component does not materially affect the condition of the whole system. A Weibull distribution of time to failure and a negative exponential distribution of estimated repair cost are assumed for analytic amenability. An optimal “repair cost limit” policy is developed that minimizes the average cost per unit time for repairs and replacement. It is shown that the optimal policy is finite and unique.     

A geometric-process maintenance model for a deteriorating system under a random environment

This paper studies a geometric-process maintenance-model for a deteriorating system under a random environment. Assume that the number of random shocks, up to time t, produced by the random environment forms a counting process. Whenever a random shock arrives, the system operating time is reduced. The successive reductions in the system operating time are statistically independent and identically distributed random variables. Assume that the consecutive repair times of the system after failures, form an increasing geometric process; under the condition that the system suffers no random shock, the successive operating times of the system after repairs constitute a decreasing geometric process. A replacement policy N, by which the system is replaced at the time of the failure N, is adopted. An explicit expression for the average cost rate (long-run average cost per unit time) is derived. Then, an optimal replacement policy is determined analytically. As a particular case, a compound Poisson process model is also studied.     

Cost analysis of a two-unit warm standby reliability system with two types of repair facilities

This paper deals with a two-unit warm standby system. These units are identical, but have different failure rates and repair time distributions, when failed in operating or standby state. If the unit fails in operating state, we wait for the repairman for some maximum time or until the other unit fails, and if the unit fails in standby state we wait for the repairman until the other unit fails. On the failure of the second unit or on the completion of the maximum time, we call the repairman immediately at the higher cost.The system has been analysed to determine the various reliability measures by using semi-Markov processes and regenerative processes. Numerical results pertaining to some particular cases are also added.     

A Geometric Process $delta$-Shock Maintenance Model

A geometric process $delta$ -shock maintenance model for a repairable system is introduced. If there exists no shock, the successive operating time of the system after repair will form a geometric process. Assume that the shocks will arrive according to a Poisson process. When the interarrival time of two successive shocks is smaller than a specified threshold, the system fails, and the latter shock is called a deadly shock. The successive threshold values are monotone geometric. The system will fail at the end of its operating time, or the arrival of a deadly shock, whichever occurs first. The consecutive repair time after failure will constitute a geometric process. A replacement policy $N$ is adopted by which the system will be replaced by a new, identical one at the time following the $N$th failure. Then, for the deteriorating system, and the improving system, an optimal policy $N^{ast}$ for minimizing the long-run average cost per unit time is determined analytically.      

Continuous-time predictive-maintenance scheduling for adeteriorating system

A predictive-maintenance structure for a gradually deteriorating single-unit system (continuous time/continuous state) is presented in this paper. The proposed decision model enables optimal inspection and replacement decision in order to balance the cost engaged by failure and unavailability on an infinite horizon. Two maintenance decision variables are considered: the preventive replacement threshold and the inspection schedule based on the system state. In order to assess the performance of the proposed maintenance structure, a mathematical model for the maintained system cost is developed using regenerative and semi-regenerative processes theory. Numerical experiments show that the s-expected maintenance cost rate on an infinite horizon can be minimized by a joint optimization of the replacement threshold and the a periodic inspection times. The proposed maintenance structure performs better than classical preventive maintenance policies which can be treated as particular cases. Using the proposed maintenance structure, a well-adapted strategy can automatically be selected for the maintenance decision-maker depending on the characteristics of the wear process and on the different unit costs. Even limit cases can be reached: for example, in the case of expensive inspection and costly preventive replacement, the optimal policy becomes close to a systematic periodic replacement policy. Most of the classical maintenance strategies (periodic inspection/replacement policy, systematic periodic replacement, corrective policy) can be emulated by adopting some specific inspection scheduling rules and replacement thresholds. In a more general way, the proposed maintenance structure shows its adaptability to different possible characteristics of the maintained single-unit system     

Optimal stocking for replacement with minimal repair

Joint stocking and replacement model with minimal repair at failure is considered. A recursive relationship among the optimal replacement intervals is obtained, which shows that replacement intervals are an increasing sequence due to the inventory carrying cost. Using the relationship, a procedure is given for determining how many units to purchase on each order and when to replace each unit after it has begun operating so as to minimize the total cost per unit time over an infinite time span. The problem can be simplified if equal replacement intervals are assumed, and the solution is very close to that of the unconstrained problem.     

Periodic-replacement models with threshold levels

The authors suggest five replacement policies where a unit is replaced at periodic times, jT(j=1,2, . . .), and the replacement cost is expensive when some number of events occurring in (0,t) is greater than a threshold level. The usual models for inspection, periodic replacement, block replacement, parallel systems, and cumulative damage can be transformed into replacement models with threshold levels. The mean cost-rate of each model is obtained, using well-known results of reliability theory. The optimum replacement time which minimizes the cost-rate of an inspection model is discussed and shown to exist uniquely     

Optimal replacement policies for k-out-of-nsystems

The authors study a discrete-time, infinite-horizon, dynamic programming model for the replacement of components in a binary k -out-of-n:F system. The goal is to trade off the component replacement and system failure costs. Under the criterion of minimizing the long-run average cost per period, it is optimal to follow a critical component policy (CCP), viz., a policy specified by a critical component set and the rule: replace a component if and only if it is failed and is in the critical component set. Computing an optimal CCP is a binary nonlinear programming problem, which can be solved by searching through a set with O(n^k-1) points. This approach to finding an optimal CCP is practical when k is small. In particular, assuming s-independent components, it requires O(n^2k-1) calculations. The authors analyze in detail the two most important cases with small k: the series (1-out-of-n:F) system and the 2-out-of-n:F system     

Optimal inspection when the system is repaired upon detection of failure

In Barlow and Proschan (Mathematical Theory of Reliability, 1965, Section 3.2) a cost model is presented for a system subject to random failure and whose state is known only by inspection. Upon detection of failure repair (or replacement) is performed and the system is then as good as new. A method of determining the inspection schedule which minimizes the long run average (expected) cost per unit time is proposed. In this present paper we look closer into the problem of finding an optimal inspection schedule for this model. Some new results, which are useful in connection with the computation of the optimal inspection schedule, are given.     

Extended block replacement policy of a system subject to shocks

A generalization of the block replacement (BR) policy is proposed and analyzed for a system subject to shocks. Under such a policy, an operating system is preventively replaced by new ones at times i·T (i=1,2,3,...) independently of its failure history. If the system fails in: (a) ((i-1)·T, (i-1)·T+T₀), it is either replaced by a new one or minimally repaired; or (b) ((i-1)·T+T₀, i·T), it is either minimally repaired or remains inactive until the next planned replacement. The choice of these two actions is based on some mechanism (modeled as random) which depends on the number of shocks since the latest replacement. The average cost rate is obtained using the results of renewal reward theory. The model with two variables is transformed into a model with one variable and the optimum policy is discussed. Various special cases are considered. The results extend many of the well-known results for BR policies     

Estimating component-defect probability from masked systemsuccess/failure data

Consider a system of k components that fails whenever there is a defect in at least one of the components. Due to cost and time constraints it is not feasible to learn exactly which components are defective. Instead, test procedures ascertain that the defective components belong to some subset of the k components. This phenomenon is termed masking. The authors describe a 2-stage procedure in which a sample of masked subsets is subjected to intensive failure analysis. This enables maximum-likelihood estimation of the defect probability of each individual component and leads to diagnosis of the defective components in future masked failures