Replacement and Repair Optimization for Production Systems Under Random Production Waits

This study considers a repairable production system operated under an age-based preventive replacement policy that is subject to independent random production waits and failures. In addition to the age-based replacement policy, we propose a maintenance model that uses production waits to schedule preventive replacement. That is, a decision maker can preventively replace the system either during a production wait or at the age threshold, whereas if a failure occurs during production, the decision maker must decide whether to perform a minimal repair or a corrective replacement to restore the system. Under the above setting, we develop a semi-Markov decision process (SMDP) to obtain the optimal maintenance policy that minimizes the long-run average maintenance cost rate. We establish the existence of the optimal maintenance policy and provide an algorithm to numerically obtain the optimal action for each state. We further generalize the model to incorporate imperfect maintenance and the nonhomogeneous arrival of production waits. In the latter case, it is computationally intractable to optimize the SMDP using a value iteration algorithm due to the curse of dimensionality. To address this challenge, we further develop an approximate dynamic programming framework to generate high-quality solutions. An attractive feature of our model is its generality, such that the model includes many existing maintenance models as special cases. A real-world example from a steel factory is used to demonstrate the proposed model.