Component Repairs When To Perform
Component Repairs When To Perform
Component Repairs When To Perform
Keywords: repairable system, virtual age, component repairs, intensity model, proportional hazard model, proportional intensity
model.
represent the response of the component repair and operating
SUMMARY & CONCLUSIONS process, and they are those measures that reflect the
successfulness of the process, and whose desired benchmarks
In this paper, a new indicator is proposed, that reflects the form the goals of the process itself. These output variables can
state of a major component in function of the ages of the be minimum costs or downtime and/or maximum availability
(groups of) parts of which it consists. The contribution of the or reliability, among others.
ages of the parts to the state of the component is defined by
their weights. The indicator can be interpreted as the virtual
age of the component, and can therefore be used to define age- (Decisions)
reduction factors of different types of repair in a virtual age or
Repair Interval?
age-reduction process. The state indicator is used as the time What parts to replace?
Costs
In capital-intensive industries, maintenance costs form a The input to the process is represented by the Key Process
big part of the total operating & production costs. According Input Variables (KPIV), and they can be classified into two
to Campbell (1995), maintenance costs as a percentage of total groups: controlled and uncontrolled KPIV. Uncontrolled
value-added costs can be as high as 20-50% for mining, 15- KPIV influence the output of the process, yet cant be
25% for primary metal and 3-15% for processing and controlled. KPIV can be health information such as metal
manufacturing industries. From these figures, one would particles in the lubricating oil or vibration measurements,
expect that critical efforts be directed towards the optimization operating environment and the state of the system
of major component performance, as they account for a (component), among others. The controlled KPIV are the only
considerable part of these costs. However, in practice this is means by which the process can be steered by the user or
rarely the case. controller. In the case of non-repairable components, this is a
In contrast to most minor components and parts, major replacement strategy only (preventive or predictive), yet in the
components are repaired and not replaced upon failure and/or case of a repairable component, these are the repair interval or
at preventive/predictive intervals. Therefore, the optimization strategy, the repair itself (to what extent to repair the
of component repair/replacement strategies is more complex component) and the replacement interval or strategy (when to
in this case. Moreover, it does not only involve deciding when replace the component rather than to repair it).
to replace, but also when to repair, which in itself creates The key for optimizing the component repair and
another issue to be addressed, that is, to what extent to repair operating process is to quantify the relationship between KPIV
the component. The latter question is what makes the and KPOV. This relationship then will translate the goals or
optimization of major components complex, as there are many benchmarks of the KPOV into decisions regarding the
different ways to carry out a repair. controlled KPIV.
The component repair problem can be seen as an input- There have been several attempts to quantify this
output process, where decisions can be made regarding the relationship in the reliability literature. The majority of them
repair process itself that affect the posterior performance of use an intensity process (t ) of the counting process of
the component, as shown in Figure 1. component failures N (t ) , defined as follows
In this figure, the Key Process Output Variables (KPOV)
The objective of the decision process is to find the set and where,
repair interval t p that minimize the expected costs per unit S A (u | x(t + )) = Pr(Tt > u | A, x(t + )) = 1 F A (u | x(t + ))
time until the next repair (over the current history). A+ u
The decision policy is called myopic because it does not = exp( ( s )ds)
take into account the consequences of the repair decision and A
interval beyond the actual history, and therefore by definition Tt = T is the time from repair at t to the first failure after t, and
is sub-optimal. The information that is available to the x(t + ) is the covariate vector just after repair at t. It is assumed
decision-maker (a tradesperson in the workshop) is the
that the covariate vector is fixed over the current history, as
information on the age of every part at the beginning of the
interval, and whether the part failed or not at the end of the discussed at the end of section 3. Then, for x(t + ) = x ,
exp( ' x )
previous history. The cost consequence of failure might S ( A + u)
depend on the parts that failed, but this would require a more S A (u | x) = 0
, (9)
complicated competing-risk model (in which the S0 ( A)
components failure intensity is the sum of the individual parts where
failure intensities) whose parameters may be difficult to u u
estimate due to lack of information. S0 (u ) = exp 0 ( s )ds = exp . (10)
0
4.2 Calculating the Optimal Policy The expected time until the next repair is
tp
The ages of the parts just before the possible repair at time E[min(T , t p )] = S A (u | x))du (11)
t are represented by the vector s(t ) = [ s1 (t ), s 2 (t ),..., s k (t )] , 0
and the ages of the parts just after the possible repair at time t As a criterion for the calculation of the optimal
by the vector s(t + ) = [ s1 (t + ), s 2 (t + ),..., s k (t + )] . The state replacement decision and the repair interval t p we will use the
vector of the component just before the repair is expected costs per unit time for the current history, defined as
f = [ f 1 , f 2 ,..., f k ] , where f j = 1 if the jth part is in failed E[CT ]
(d , t p ) = . (12)
state and 0 otherwise. The decision vector is E[min(T , t p )]
let us assume that C Ff = $8000 , C Fp = $1000 and that the Table 1 Optimal Decisions for First Repair
parameters of the power-law intensity are = 3.0 and Next, let us assume that the optimal decision is
= 3000 . We will assume only one time-independent implemented; that is, only part 1 is replaced, and let us assume
covariate, representing the operating condition, which takes that part 1 fails again after 600 hours of operation. The ages of
the value 0 for operating condition 1 and the value 1 for the parts at that time are [600, 1848, 1848, 1848]. Table 2
operating condition 2. The coefficient for this covariate is displays the results of the calculation.
assumed to be 0.50, and therefore the failure intensity In this case, the optimal repair decision is different for
associated with operating condition 2 is 1.65 times the failure operating conditions 1 and 2. For the more severe operating
intensity for operating condition 1. condition, in addition to part 1, part 3 has to be replaced, while
The component starts off with all parts having 0 for operating condition 1 only part 1 has to be replaced. This
accumulated operating hours, and the only feasible repair shows that the destination of the component (operating
policy is replacing no parts at all. In case of operating condition) has an influence on the optimal repair decision.
condition 1 the optimal repair interval is 1248 hours at a cost From this example it can be seen that the selection of
of $1.2123 per operating hour, and in case of operating which parts to replace in a repair can have great impact on the
condition 2 the optimal repair interval is 1057 hours at a cost expected costs per hour. The proposed model can identify
of $1.4321 per operating hour. what the best parts to replace are, taking into account time-
Now, let us assume that the component started off in independent covariates, in this case one, the operating
operating condition 1 and reaches the optimal repair interval condition. In the example, part 1 had the highest weight,
before failure. Then, at the time, all parts will have 1248 which indicates that the contribution to the components
operating hours, and none will be in a failed state. After repair, failure intensity of this part is significant compared to the
the component can be put back into operation in either other parts. As the cost of replacing this part is relatively
operating condition 1 or 2. Denoting the repair decision by a cheap, this part will be replaced most frequently, followed by
vector d, as introduced in section 4.2, the feasible decisions parts 3, 2 and 4 respectively.
with their results for both operating conditions can be seen in
Operating Condition 1 Operating Condition 2
Table 1. The table displays the optimal repair interval for each Decision tp* Costs/Hour Decision tp* Costs/Hour
feasible repair. It can be seen that the optimal repair decision [1,0,0,0] 1304 3.2465 [1,0,0,0] 1074 4.2145
for both operating conditions is to replace part 1 only, [1,0,0,1] 2208 6.3392 [1,0,0,1] 1844 7.9578
[1,0,1,0] 1792 3.3290 [1,0,1,0] 1500 4.0524
although the optimal repair interval for operating condition 1 [1,0,1,1] 2532 5.7427 [1,0,1,1] 2133 6.8917
is greater than that for operating condition 2. Also, the [1,1,0,0] 1952 4.8861 [1,1,0,0] 1627 6.1041
expected costs per hour are higher for operating condition 2. [1,1,0,1] 2606 7.3224 [1,1,0,1] 2188 9.0029
[1,1,1,0] 2329 4.5598 [1,1,1,0] 1966 5.4309
The table also shows that there is a considerable difference in [1,1,1,1] 2907 6.5705 [1,1,1,1] 2460 7.7621
costs/hour for different repair decisions for either operating
condition 1 or 2. Finally, it can be seen that although the Table 2 Optimal Decisions for Second Repair
optimal repair decision is the same for both operating
conditions, that this is not necessarily the case, as the ordered 6. CONCLUSIONS
list of feasible repair decisions (according to their expected
costs per hour) are different. This means that the components The proposed indicator establishes a relationship between
destination (operating condition 1 or 2) does have an influence the ages of the parts of the component, and its state. It reflects
on the decision what parts to replace in the repair. the real age of the component, and can be useful to relate
The optimal decision of replacing part 1 in both cases is repair strategies and the activities of which they consist to age-
logical, as the weight of part 1, 0.60, is high compared to its reduction factors. The state indicator can be useful by itself,
The authors wish to thank the Natural Sciences and Dragan Banjevic, PhD
Engineering Research Council (NSERC) of Canada, Materials Department of Mechanical and Industrial Engineering
and Manufacturing Ontario (MMO) of Canada, and the CBM University of Toronto
Consortium members for their financial support. 5 Kings College Road
Toronto, Ontario, Canada, M5S 3G8
REFERENCES
e-mail: banjev@mie.utoronto.ca
1. J.D. Campbell, Uptime: strategies for excellence in
maintenance management, 1995, p 2, Productivity Press, Dragan Banjevic is Project Director of the Condition-Based
Portland, Oregon, USA. Maintenance laboratory at the Department of Mechanical and
2. D.R. Cox, Regression Models and Life Tables, 1972a, Industrial Engineering of the University of Toronto. He
Journal of the Royal Statistical Society, vol. B34, pp 187- teaches in both the University's Department of Statistics and
220. the Department of Mechanical and Industrial Engineering.
3. D.R. Cox, The Statistical Analysis of Dependencies in
Point Processes, 1972b, in: Stochastic Point Processes, Andrew K. S. Jardine, PhD, CEng, PEng
P. A. Levis (ed), pp 55-66, Wiley, New York, USA. Department of Mechanical and Industrial Engineering
4. P.J. Vlok, J.L. Coetzee, D. Banjevic, A.K.S. Jardine, V. University of Toronto
Makis, Optimal component replacement decisions using 5 Kings College Road
vibration monitoring and the proportional-hazards Toronto, Ontario, Canada, M5S 3G8
model, 2002, Journal of the Operational Research
Society, vol. 53, pp 193-202. e-mail: jardine@mie.utoronto.ca
5. M. Kijima, Some results for repairable systems with
general repair, 1989, Journal of Applied Probability, vol. Andrew Jardine is Professor in the Department of Mechanical
26, pp 89-102. and Industrial Engineering and principal investigator in the
6. M.A.K. Malik, Reliable preventive maintenance Condition-Based Maintenance Laboratory at the University of
scheduling, 1979, AIIE Transactions, vol. R28, pp 331- Toronto, Canada. He also serves as a Senior Associate
332. Consultant to the Enterprise Asset Management Group of
7. D. Lugtigheid, D. Banjevic, A.K.S. Jardine, Modelling IBM's Business Consulting Services.
repairable system reliability with explanatory variables