Inventory management in railway sleepers: A simulation model for replacement strategies

This paper describes the development of a simulation model to assess the inventory requirements of alternative rail sleeper replacement strategies. The main aim of the model is to determine the optimal replacement strategy, given replacement costs and resultant train operating cost benefits. We consider the replacement problem under the following assumptions: The time to failure under constant stress follows a Weibull distribution and the scale parameter is a function of stress level and the three stress levels under normal (all adjacent units are good), medium-stress (one adjacent unit has failed) and high-stress conditions (two adjacent units are failed) are considered. The cumulative exposure model is used to model the failure distributions. The operational cost per unit time depends on the maximum number of consecutive failed units. The replacement cost consists of the fixed cost and variable cost proportional to the number of units replaced. A finite horizon is considered and total expected cost is a criterion for comparing the proposed policies. The model has been tested using rail system data and the results are presented in this paper

Preventive replacement for belligerent systems

A mortar is commonly used as an indirect firing weapon to support close fires with a variety of ammunition. There are mortar weapons with various shells. Each type of shells fired by mortars does damage to a weapon when the total damage on a mortar weapon reaches the tolerance limit, the mortar weapon either fails or explodes, leading to a compulsory replacement which is costly. In order to maintain the mortar weapons and archers in wars, a research was conducted to find the best number of mortar shells that will be fired until a preventive replacement for mortar weapons is implemented

A Periodicity Metric for Assessing Maintenance Strategies

Organised by: Cranfield UniversityThe maintenance policy in manufacturing systems is devised to reset the machines functionality in an economical fashion in order to keep the products quality within acceptable levels. Therefore, there is a need for a metric to evaluate and quantify function resetting due to the adopted maintenance policy. A novel metric for measuring the functional periodicity has been developed using the complexity theory. It is based on the rate and extent of function resetting. It can be used as an important criterion for comparing the different maintenance policy alternatives. An industrial example is used to illustrate the application of the new metric.Mori Seiki – The Machine Tool Company; BAE Systems; S4T – Support Service Solutions: Strategy and Transitio

A study of postponed replacement in a delay time model

We develop a delay time model for a one component system with postponed replacement to analyze situations in which maintenance might not be executed immediately upon discovery of a defect in the system. Reasons for postponement are numerous: to avoid production disruption or unnecessary or ineffective replacement; to prepare for replacement; to extend component life; to wait for an opportunity. This paper explores conditions that make postponement cost-effective. We are interested in modelling the reality in which a maintainer either prioritizes functional continuity or is not confident of the inspection test indicating a defective state. In some cases more frequent inspection and a longer time limit for postponement are recommended to take advantage of maintenance opportunities, characterized by their low cost, arising after a positive inspection. However, when the cost of failure increases, a significant reduction in the time limit of postponement interval is observed. The examples reveal that both the time to defect arrival and delay time have a significant effect upon the cost-effectiveness of maintenance at the limit of postponement. Also, more simply, we find that opportunities must occur frequently enough and inspection should be a high quality procedure to risk postponement

An study of cost effective maintenance policies: Age replacement versus replacement after N minimal repairs

In this paper we consider the inspection and maintenance of a system under two types of age-dependent failures, revealed minor failures (R) and unrevealed catastrophic failures (U). Periodic inspections every T units of time are carried out to detect U failures, leading to the system replacement when one is discovered. R failures are followed by a minor repair. In addition the system is preventively replaced at MT or after the Nth R failure whichever comes first. The costs of minimal repair and replacement after N minor failures depend on age and history of failures. Non-perfect inspections are assumed, providing false positives when no U failure has happened or false negatives when a U failure is present. The long-run cost per unit of time along with the optimum policy (T*, M*, N*) are obtained. We explore conditions under which both strategies of preventive maintenance are profitable, comparing with suboptimal policies when only one of them is performed. Maintenance of infrastructures illustrates the model conditions

A condition-based maintenance policy for multi-component systems with a high maintenance setup cost

Condition-based maintenance (CBM) is becoming increasingly important due to the development of advanced sensor and ICT technology, so that the condition data can be collected remotely. We propose a new CBM policy for multi-component systems with continuous stochastic deteriorations. To reduce the high setup cost of maintenance, a joint maintenance interval is proposed. With the joint maintenance interval and control limits of components as decision variables, we develop a model for the minimization of the average long-run maintenance cost rate of the systems. Moreover, a numerical study on a case of a wind power farm consisting of a large number of non-identical components is performed, including a sensitivity analysis. At last, our policy is compared to a corrective-maintenance-only policy

A SYSTEMATIC SURVEY OF THE MAINTENANCE MODELS

A systematic survey of the maintenance models has been carried out, which may help the maintenance engineer to have a total picture on maintenance policies. Maintenance policies dis- cussed in the literature have been studied, inter-related and classified into three groups viz. (I) Re- placement/repair at failure, (II) Planned maintenance (repair/replacement) at pre-determined intervals based on number of failures or otherwise and (Ill) Condition based maintenance. The above number of groups are necessary and sufficient for the purpose of methodical surveying of the publications on the topic