An Extended Sequential Imperfect Preventive Maintenance Model with Improvement Factors

This article presents a generalization of the imperfect sequential preventive maintenance (PM) policy with minimal repair. As failures occur, the system experiences one of two types of failures: a Type-I failure (minor), rectified by a minimal repair; or a Type-II failure (catastrophic) that calls for an unplanned maintenance. In each maintenance period, the system is maintained following the occurrence of a Type-II failure or at age, whichever takes place first. At the Nth maintenance, the system is replaced rather than maintained. The imperfect PM model adopted in this study incorporates with improvement factors in the hazard-rate function. Taking age-dependent minimal repair costs into consideration, the objective consists of finding the optimal PM and replacement schedule that minimize the expected cost per unit time over an infinite time-horizon.     

Adaptive Sequential Preventive Maintenance Policy and Bayesian Consideration

This article proposes an adaptive sequential preventive maintenance (PM) policy for which an improvement factor is newly introduced to measure the PM effect at each PM. For this model, the PM actions are conducted at different time intervals so that an adaptive method needs to be utilized to determine the optimal PM times minimizing the expected cost rate per unit time. At each PM, the hazard rate is reduced by an amount affected by the improvement factor which depends on the number of PM's preceding the current one. We derive mathematical formulas to evaluate the expected cost rate per unit time by incorporating the PM cost, repair cost, and replacement cost. Assuming that the failure times follow a Weibull distribution, we propose an optimal sequential PM policy by minimizing the expected cost rate. Furthermore, we consider Bayesian aspects for the sequential PM policy to discuss its optimality. The effect of some parameters and the functional forms of improvement factor on the optimal PM policy is measured numerically by sensibility analysis and some numerical examples are presented for illustrative purposes.     

Optimal preventive policies for imperfect maintenance models with replacement first and last

ABSTRACT

This paper proposes preventive replacement policies for an operating system which may continuously works for N jobs with random working times and is imperfectly maintained upon failure. As a failure occurs, the system suffers one of the two types of failures based on some random mechanism: type-I (repairable or minor) failure is rectified by a minimal repair, or type-II (non repairable or catastrophic) failure is removed by a corrective replacement. A notation of preventive replacement last model is considered in which the system is replaced before any type-II failure at an operating time T or at number N of working times, whichever occurs last. Comparisons between such a preventive replacement last and the conventional replacement first are discussed in detail. For each model, the optimal schedule of preventive replacement that minimizes the mean cost rate is presented theoretically and determined numerically. Because the framework and analysis are general, the proposed models extend several existing results.     

NONPARAMETRIC META‐ANALYSIS FOR MINIMAL‐REPAIR SYSTEMS

We consider the situation that repair times of several identically structured technical systems are observed. As an example of such data we discuss the Boeing air conditioner data, consisting of successive failures of the air conditioning system of each member of a fleet of Boeing jet airplanes. The repairing process is assumed to be performed according to a minimal‐repair strategy. This reflects the idea that only those operations are accomplished that are absolutely necessary to restart the system after a failure. The ‘after‐repair‐state’ of the system is the same as it was shortly before the failure. Clearly, the observed repair times contain valuable information about the repair times of an identically structured system put into operation in the future. Thus, for statistical analysis and prediction, it is certainly favourable to take into account all repair times from each system. The resulting pooled sample is used to construct nonparametric prediction intervals for repair times of a future minimal‐repair system. To illustrate our results we apply them to the above‐mentioned data set. As expected, the maximum coverage probabilities of prediction intervals based on two samples exceed those based on one sample. We show that the relative gain for a two‐sample prediction over a one‐sample prediction can be substantial. One of the advantages of the present approach is that it allows nonparametric prediction intervals to be constructed directly. This provides a beneficial alternative to existing nonparametric methods for minimal‐repair systems that construct prediction intervals via the asymptotic distribution of quantile estimators. Moreover, the prediction intervals presented here are exact regardless of the sample size.     

Optimal Age Policy for a Used System with Imperfect Preventive Maintenance and Cumulative Damage Model

In this article, the concept of imperfect preventive maintenance is discussed and an age maintenance policy is developed based on the cumulative damage model for a used system with initial variable damage. The deterioration of the system is assumed to suffer the non-homogeneous Poisson shocks which can be divided into two types with stochastic probability: Type-I shock (minor) yields a random amount of additive damage of the system, or Type-II shock (catastrophic) causes the system to fail. An age preventive maintenance policy T is presented in which the system undergoes preventive maintenance at a scheduled lifetime T, or corrective maintenance at first Type-II shock and the total damage exceeds a threshold level, whichever occurs first. The objective is to determine the optimal preventive maintenance schedule such that the expected cost rate is minimized. The optimal solution is derived analytically and discussed numerically.     

A Bivariate Optimal Replacement Policy for a System With Age-dependent Minimal Repair and Cumulative Repair-cost Limit

In this article, a repairable system with age-dependent failure type and minimal repair based on a cumulative repair-cost limit policy is studied, where the information of entire repair-cost history is adopted to decide whether the system is repaired or replaced. As the failures occur, the system has two failure types: (i) a Type-I failure (minor) type that is rectified by a minimal repair, and (ii) a Type-II failure (catastrophic) type that calls for a replacement. We consider a bivariate replacement policy, denoted by (n,T), in which the system is replaced at life age T, or at the n-th Type-I failure, or at the kth Type-I failure (k < n and due to a minor failure at which the accumulated repair cost exceeds the pre-determined limit), or at the first Type-II failure, whichever occurs first. The optimal minimum-cost replacement policy (n,T)* is derived analytically in terms of its existence and uniqueness. Several classical models in maintenance literature could be regard as special cases of the presented model. Finally, a numerical example is given to illustrate the theoretical results.     

Optimization of continuous and discrete scheduled times for a cumulative damage system with age-dependent maintenance

Abstract

This paper presents a preventive replacement problem when a system is operating successive works with random times and suffering stochastic shocks. The works cause random amount additive damage to the system, and the system fails whenever the cumulative damage reaches a failure level threshold. As an external shock occurs, the system experiences one of the two types of shocks with age-dependent maintenance mechanism: type-I (minor) shock is rectified by a minimal repair, or type-II (catastrophic) shock causes the system to fail. To control the deterioration process, preventive replacement is scheduled to replace the system at a continuous age T or at a discrete number N of working cycles, whichever occurs first, and corrective replacement is performed immediately whenever the system fails due to either shock or damage. The optimal preventive replacement schedule that minimizes the expected cost rate is discussed analytically and computed numerically. The proposed model provides a general framework for analyzing maintenance policies and extends several existing results.     

Power Law Selection Model for Repairable Systems

A repairable system, under minimal repair, is usually modeled according to a Non-Homogeneous Poisson Process (NHPP) assuming a Power Law intensity function. A traditional approach considers iid NHPPs in order to conduct a statistical analysis based on a sample of systems. However, systems might be heterogeneous due to unmeasured variables such as age, suppliers, and so on. In order to verify this assumption a frequentist approach is proposed in this article. Some possible model scenarios considering different systems heterogeneity are compared using likelihood ratio tests and information criteria. Real data sets illustrate the proposed methodology.     

The Optimal Preventive Maintenance Policy for the Multistate System Profit

Here, the problem of preventive maintenance optimization for the multistate system is investigated considering a three-state system. The optimal numbers of preventive maintenance that maximize the expected profit values of this system are evaluated and these numbers are then used to increase the three-state system availability.     

Age Replacement Policy with a Safety Constraint via the Bayesian Method

Consider a system that is subject to shocks that arrive according to a non homogeneous Poisson process. As the shocks occur, the system has m + 1 failure modes including the following: (i) a non repairable failure (catastrophic) mode that calls for a replacement and (ii) m repairable failure (non catastrophic) modes that are rectified by minimal repairs. In this article, we propose an age-replacement model with minimal repair based on using the natural conjugate prior of Bayesian method. In addition, a safety constraint is considered to control the risk of occurring catastrophic failures in a specified time interval. The minimum-cost replacement policy is studied in terms of its existence and safety constraint. A numerical example is also presented to illustrate the proposed model.     

Bayesian inference for power law processes with applications in repairable systems

Statistical models for recurrent events are of great interest in repairable systems reliability and maintenance. The adopted model under minimal repair maintenance is frequently a nonhomogeneous Poisson process with the power law process (PLP) intensity function. Although inference for the PLP is generally based on maximum likelihood theory, some advantages of the Bayesian approach have been reported in the literature. In this paper it is proposed that the PLP intensity be reparametrized in terms of (β,η), where β is the elasticity of the mean number of events with respect to time and η is the mean number of events for the period in which the system was actually observed. It is shown that β and η are orthogonal and that the likelihood becomes proportional to a product of gamma densities. Therefore, the family of natural conjugate priors is also a product of gammas. The idea is extended to the case that several realizations of the same PLP are observed along overlapping periods of time. Some Monte Carlo simulations are provided to study the frequentist behavior of the Bayesian estimates and to compare them with the maximum likelihood estimates. The results are applied to a real problem concerning the determination of the optimal periodicity of preventive maintenance for a set of power transformers. Prior distributions are elicited for β and η based on their operational interpretation and engineering expertise.     

Availability of a periodically inspected system with random repair or replacement times

The availability of systems undergoing periodic inspections is studied in this paper. A perfect repair or replacement of a failed system is carried out requiring either a constant or a random length of time. In Model A, the system is assumed to be as good as new on completion of inspection or repair. For Model B, no maintenance or corrective actions are taken at the time of inspection if the system is still working, and the condition of the system is assumed to be the same as that before the inspection. Unlike that studied in a related paper by Sarkar and Sarkar (J. Statist. Plann. Inference 91 (2000) 77.), our model assumes that the periodic inspections take place at fixed time points after repair or replacement in case of failure. Some general results on the instantaneous availability and the steady-state availability for the two models are presented under the assumption of random repair or replacement time.     

Optimal scheduling replacement policies for a system with multiple random works

From the economical viewpoint in reliability theory, this paper addresses a scheduling replacement problem for a single operating system which works at random times for multiple jobs. The system is subject to stochastic failure which results the imperfect maintenance activity based on some random failure mechanism: minimal repair due to type-I (repairable) failure, or corrective replacement due to type-II (non-repairable) failure. Three scheduling models for the system with multiple jobs are considered: a single work, N tandem works, and N parallel works. To control the deterioration process, the preventive replacement is planned to undergo at a scheduling time T or the job's completion time of for each model. The objective is to determine the optimal scheduling parameters (T^* or N^*) that minimizes the mean cost rate function in a finite time horizon for each model. A numerical example is provided to illustrate the proposed analytical model. Because the framework and analysis are general, the proposed models extend several existing results.     

Condition-based maintenance policy for linear consecutive-k-out-of-n: F system

In the article, a condition-based maintenance policy is proposed for a linear consecutive-k-out-of-n: F system. The failure times of components are assumed to be independent and identically distributed. It is assumed that the component states in the system can be known at any time and the system failure can be detected immediately. The preventive maintenance action is based on the number of working components in minimal cut sets of the system. If there is at least one minimal cut set consisting of only one working component, the system is maintained preventively after a certain time interval. The proposed policy is compared with corrective maintenance and age-based maintenance policies. As an extended case, it is assumed that the component states can only be known by inspection, but the system failure can be detected immediately. In this case, the system is inspected periodically and is also maintained preventively based on the system state at inspection. Numerical examples are studied to evaluate the performance of the proposed policy and investigate the effects of cost parameters on the expected cost rate.     

An optimal age-replacement policy for a simple repairable system with delayed repair

In this article, a simple repairable system (i.e., a repairable system consisting of one component and one repairman) with delayed repair is studied. Assume that the system after repair is not “as good as new”, and the degeneration of the system is stochastic. Under these assumptions, using the geometric process repair model, we consider a replacement policy T based on system age under which the system is replaced when the system age reaches T. Our problem is to determine an optimal replacement policy T*, such that the average cost rate (i.e., the long-run average cost per unit time) of the system is minimized. The explicit expression of the average cost rate is derived, the corresponding optimal replacement policy T* can be determined by minimizing the average cost rate of the system. Finally, a numerical example is given to illustrate some theoretical results and the model's applicability.     

Goodness-of-Fit of the Distribution of Time-to-First-Occurrence in Recurrent Event Models

Imperfect repair models are a class of stochastic models that deal with recurrent phenomena. This article focuses on the Block, Borges, and Savits (1985) age-dependent minimal repair model (the BBS model) in which a system that fails at time t undergoes one of two types of repair: with probability p(t), a perfect repair is performed, or with probability 1-p(t), a minimal repair is performed. The goodness-of-fit problem of interest concerns the initial distribution of the failure ages. In particular, interest is on testing the null hypothesis that the hazard rate function of the time-to-first-event-occurrence, λ(·), is equal to a prespecified hazard rate function λ₀(·). This paper extends the class of hazard-based smooth goodness-of-fit tests introduced in Peña (1998a) to the case where data accrual is from a BBS model. The goodness-of-fit tests are score tests derived by reformulating Neyman's idea of smooth tests in terms of hazard functions. Omnibus as well as directional tests are developed and simulation results are presented to illustrate the sensitivities of the proposed tests for certain types of alternatives.     

Modified branching process for the reliability analysis of complex systems: Multiple-robot systems

Current design practice is usually to produce a safety system which meets a target level of performance that is deemed acceptable by the regulators. Safety systems are designed to prevent or alleviate the consequences of potentially hazardous events. In many modern industries the failure of such systems can lead to whole system breakdown. In reliability analysis of complex systems involving multiple components, it is assumed that the components have different failure rates with certain probabilities. This leads into extensive computational efforts involved in using the commonly employed generating function (GF) and the recursive algorithm to obtain reliability of systems consisting of a large number of components. Moreover, when the system failure results in fatalities it is desirable for the system to achieve an optimal rather than adequate level of performance given the limitations placed on available resources. This paper concerns with developing a modified branching process joint with generating function to handle reliability evaluation of a multi-robot complex system. The availability of the system is modeled to compute the failure probability of the whole system as a performance measure. The results help decision-makers in maintenance departments to analyze critical components of the system in different time periods to prevent system breakdowns.     

A geometric process repair model for a cold standby repairable system with imperfect delay repair and priority in use

In this article, a two-dissimilar-component cold standby repairable system with one repairman is studied. Assume that the repair after failure for each component is delayed or undelayed. Component 2 after repair is “as good as new” while Component 1 after repair is not, but Component 1 has priority in use. Under these assumptions, using a geometric process, we consider a replacement policy N based on the failure number of Component 1. An optimal replacement policy N* is determined by minimizing the average cost rate C(N) of the system. Finally, a numerical example is given to illustrate some theoretical results and the model applicability.     

Optimal design and maintenance of a repairable multi-state system with standby components

The configuration of a repairable system directly influences its performance measures, such as mean time between failures and steady state availability. Additionally, maintenance strategies such as corrective, preventive, and condition-based can affect the performance of the system. The objective of this work is to investigate the trade-offs between the configuration of a repairable multi-state system with binary components and its maintenance strategy. The corresponding stochastic process for the proposed model is formulated using the continuous-time Markov process and important performance measures of such a multi-state system are derived. An optimization model is introduced for the cost-effective design of this repairable multi-state system. The results are demonstrated using a numerical example for a power generation system.     

Data-Based Modeling of the Failure Rate of Repairable Equipment

A databaseof failures of many types of medical equipment was analysed,to study the dependence of failure rate on equipment age andon time since repair. The intention was to use this large datasetto assess the validity of some widely-used models of failurerate, such as the power-law and loglinear Poisson processes,and so to recommend simple and adequate models to those practitionershaving little data to discriminate between rival models. Theaim is also to illustrate a methodology for computing policycosts from failure databases. The power-law process model wasfound to fit slightly better overall than did the loglinear andlinear processes. Some related models were created to fit anobserved peaking of failure rate. The data showed a decreasinghazard of (first) failure after repair for some equipment types.This can be due to imperfect or hazardous repair, and also todiffering failure rates among a population of machines. Two simplemodels of imperfect repair were used to fit the data, and anEmpirical Bayes method was used to fit a model of variable failurerate between machines. Neglect of such variation can lead toan over-estimate of the hazardousness of repair.