Joint optimization of maintenance and spare ordering policy for a competing failure system considering product quality

Mengying Han, Qingan Qiu, Rui Peng and Tingting Wang

Journal of Risk and Reliability, 2025, vol. 239, issue 6, 1586-1608

Abstract: This paper proposes an integrated framework for maintenance, spare parts ordering, and quality control planning within a multi-state production system that is subject to two competing modes of failure: hard failure and soft failure. Hard failures occur suddenly and without any prior warning, whereas soft failures develop following the onset of a defect. The quality of the product is significantly influenced by the state of the system, as a defective system typically leads to an increase in non-conforming products. To address this, periodic inspections are conducted to detect defects early, and preventive replacements (PR) are scheduled upon identification of a defective state, which acts as a crucial quality control indicator. Corrective replacements (CR) become necessary when either a hard or soft failure occurs. The timeliness of these replacements is contingent upon spare part availability; thus, we implement a hybrid spare ordering policy to enhance responsiveness. PR and CR are executed promptly when time-based ordered spares are accessible, while a condition-based order is triggered in the event of shortages in time-based orders. To determine the optimal inspection interval and time-based spare ordering point, we analyze the renewal scenarios of the system with the objective of minimizing the expected cost rate. We propose an optimization algorithm and a simulation procedure to validate the effectiveness of our policy through numerical experiments. The results highlight the significant potential of our approach in reducing unit losses related to non-conforming products while effectively minimizing the expected cost rate.

Keywords: Maintenance; spare ordering; product quality control; failure modes; delay-time model (search for similar items in EconPapers)
Date: 2025
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Persistent link: https://EconPapers.repec.org/RePEc:sae:risrel:v:239:y:2025:i:6:p:1586-1608

DOI: 10.1177/1748006X251317570

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