Optimal replacement in the proportional hazards model and its applications in a product-service system

Condition-based maintenance is rapidly gaining favor as a way to prevent the failures of capital-intensive assets and to maintain them in good operating condition with minimum cost. A valuable and increasingly prevalent way to incorporate condition information into risk estimation is by the proportional hazards model (PHM), which explicitly includes both the age and the condition information in the calculation of the hazard function. This dissertation consists of three papers, in which the optimal replacement policies for systems whose deterioration process follows the PHM are developed under different settings; and a joint optimization of the asset and inventory management problem in the context of a product-service system is considered. In the first paper, a continuous time Markov covariate process is assumed to describe the condition of a system that is under periodic monitoring. Although the form of an optimal replacement policy for such a system in the PHM was developed previously, an approximation of the Markov process as constant within inspection intervals led to a counter-intuitive result that less frequent monitoring could yield a replacement policy with lower average cost. Accounting for possible state transitions between inspection epochs removes the approximation and eliminates the cost anomaly. A new recursive procedure to obtain the parameters of the optimal replacement policy is presented. By comparing the replacement and monitoring costs of different monitoring scheme, the value of condition information is evaluated. In the second paper, the optimal replacement policy for systems in the PHM with semi-Markovian covariate process and continuous monitoring is developed. Numerical examples and sensitivity analysis provide some insights about the suitability of a Markov approximation and the impact of the variations in the input parameters on the cost. In applying the optimal replacement policies to a product-service system, where the producers provide the use of the products to customers while retaining ownership, the coupling between the decision making for preventive replacement and the decision making for inventory management is evident. In the third paper, an integrated model is proposed for the preventive maintenance of a fleet of products and the inventory management of a hybrid manufacturing-remanufacturing system in the context of a product-service system. A joint optimization technique is developed to obtain the optimal parameters for the operational policy of the integrated model to minimize the long run average cost per unit time. In addition, the effect of the assumption that the replaced products are not sorted is evaluated

Studies in condition based maintenance using proportional hazards models with imperfect observations

Introduction and literature review -- Preliminary notations -- problem statement -- Optimal inspection period and replacement policy for CBM with imperfect information using PHM -- Problem formulation -- Formulation of the POMDP -- Long-run average cost and total long-run average cost -- Optimal inspection period -- Numerical example -- Evaluating the remaining life for equipment with unobservable states -- Practical implications -- Model assumptions -- Development of parameter estimation methods for a condition based maintenance with indirect observations -- Proposed model -- Parameters' estimation -- Optimal inspection interval and optimal replacement policy -- Reliability function and mean residual life -- Estimation of the model's parameter

DECISION SUPPORT MODEL IN FAILURE-BASED COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM FOR SMALL AND MEDIUM INDUSTRIES

Maintenance decision support system is crucial to ensure maintainability and reliability of equipments in production lines. This thesis investigates a few decision support models to aid maintenance management activities in small and medium industries. In order to improve the reliability of resources in production lines, this study introduces a conceptual framework to be used in failure-based maintenance. Maintenance strategies are identified using the Decision-Making Grid model, based on two important factors, including the machines’ downtimes and their frequency of failures. The machines are categorized into three downtime criterions and frequency of failures, which are high, medium and low. This research derived a formula based on maintenance cost, to re-position the machines prior to Decision-Making Grid analysis. Subsequently, the formula on clustering analysis in the Decision-Making Grid model is improved to solve multiple-criteria problem. This research work also introduced a formula to estimate contractor’s response and repair time. The estimates are used as input parameters in the Analytical Hierarchy Process model. The decisions were synthesized using models based on the contractors’ technical skills such as experience in maintenance, skill to diagnose machines and ability to take prompt action during troubleshooting activities. Another important criteria considered in the Analytical Hierarchy Process is the business principles of the contractors, which includes the maintenance quality, tools, equipments and enthusiasm in problem-solving. The raw data collected through observation, interviews and surveys in the case studies to understand some risk factors in small and medium food processing industries. The risk factors are analysed with the Ishikawa Fishbone diagram to reveal delay time in machinery maintenance. The experimental studies are conducted using maintenance records in food processing industries. The Decision Making Grid model can detect the top ten worst production machines on the production lines. The Analytical Hierarchy Process model is used to rank the contractors and their best maintenance practice. This research recommends displaying the results on the production’s indicator boards and implements the strategies on the production shop floor. The proposed models can be used by decision makers to identify maintenance strategies and enhance competitiveness among contractors in failure-based maintenance. The models can be programmed as decision support sub-procedures in computerized maintenance management systems

Generalized models of repairable systems: A survey via stochastic processes formalism

In this article, we survey the developments in the generalised models of repairable systems reliability during 1990s, particularly the last five years. In this field, we notice the sharp fundamental problem that voluminous complex models were developed but there is an absence of sufficient data of interest for justifying the success in tackling the real engineering problems. Instead of following the myth of using simple models to face the complex reality, we select and review some practical models, particularly the stochastic processes behind them. The Models in three quick growth areas: age models, condition monitoring technique related models, say, proportional intensity and their extensions, and shock and wearing models, including the delay-time models are reviewed. With the belief that only those stochastic processes reflecting the instinct nature of the actual physical processes of repairable systems, without excessive assumptions, may have a better chance to meet the demands of engineers and managers

Condition-based maintenance for systems with aging and cumulative damage based on proportional hazards model

This paper develops a condition-based maintenance (CBM) policy for systems subject to aging and cumulative damage. The cumulative damage is modeled by a continuous degradation process. Different from previous studies which assume that the system fails when the degradation level exceeds a specific threshold, this paper argues that the degradation itself does not directly lead to system failure, but increases the failure risk of the system. Proportional hazards model (PHM) is employed to characterize the joint effect of aging and cumulative damage. CBM models are developed for two cases: one assumes that the distribution parameters of the degradation process are known in advance, while the other assumes that the parameters are unknown and need to be estimated during system operation. In the first case, an optimal maintenance policy is obtained by minimizing the long-run cost rate. For the case with unknown parameters, periodic inspection is adopted to monitor the degradation level of the system and update the distribution parameters. A case study of Asphalt Plug Joint in UK bridge system is employed to illustrate the maintenance policy.The work described in this paper was partially supported by a theme-based project grant (T32-101/15-R) of University Grants Council, and a Key Project (71532008) supported by National Natural Science Foundation of China

Vibration covariate regression analysis of failure time data with the proportional hazards model

Please read the abstract in the section 00front of this documentDissertation (MEng (Mechanical Engineering))--University of Pretoria, 2006.Mechanical and Aeronautical Engineeringunrestricte

Condition-based maintenance—an extensive literature review

This paper presents an extensive literature review on the field of condition-based maintenance (CBM). The paper encompasses over 4000 contributions, analysed through bibliometric indicators and meta-analysis techniques. The review adopts Factor Analysis as a dimensionality reduction, concerning the metric of the co-citations of the papers. Four main research areas have been identified, able to delineate the research field synthetically, from theoretical foundations of CBM; (i) towards more specific implementation strategies (ii) and then specifically focusing on operational aspects related to (iii) inspection and replacement and (iv) prognosis. The data-driven bibliometric results have been combined with an interpretative research to extract both core and detailed concepts related to CBM. This combined analysis allows a critical reflection on the field and the extraction of potential future research directions