Spare Parts Planning And Control For Maintenance Operations
Spare parts planning and control for maintenance operationsCitation for published version (APA):Arts, J. J. (2013). Spare parts planning and control for maintenance operations. Technische UniversiteitEindhoven. 16Document status and date:Published: 01/01/2013Document Version:Publisher’s PDF, also known as Version of Record (includes final page, issue and volume numbers)Please check the document version of this publication: A submitted manuscript is the version of the article upon submission and before peer-review. There can beimportant differences between the submitted version and the official published version of record. Peopleinterested in the research are advised to contact the author for the final version of the publication, or visit theDOI to the publisher's website. The final author version and the galley proof are versions of the publication after peer review. The final published version features the final layout of the paper including the volume, issue and pagenumbers.Link to publicationGeneral rightsCopyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright ownersand it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights. Users may download and print one copy of any publication from the public portal for the purpose of private study or research. You may not further distribute the material or use it for any profit-making activity or commercial gain You may freely distribute the URL identifying the publication in the public portal.If the publication is distributed under the terms of Article 25fa of the Dutch Copyright Act, indicated by the “Taverne” license above, pleasefollow below link for the End User Agreement:www.tue.nl/taverneTake down policyIf you believe that this document breaches copyright please contact us at:openaccess@tue.nlproviding details and we will investigate your claim.Download date: 18. Mar. 2021
Spare Parts Planning and Controlfor Maintenance Operations
This thesis is number D175 of the thesis series of the Beta Research School forOperations Management and Logistics. The Beta Research School is a joint effortof the School of Industrial Engineering and the department of Mathematics andComputer Science at Eindhoven University of Technology, and the Center forProduction, Logistics and Operations Management at the University of Twente.A catalogue record is available from the Eindhoven University of Technology Library.ISBN: 978-90-386-3475-3Printed by Proefschriftmaken.nl Uitgeverij BOXPressCover Design by Roy Lurken - BureauNobelThis research has been funded by NedTrain.
Spare Parts Planning and Controlfor Maintenance OperationsPROEFSCHRIFTter verkrijging van de graad van doctor aan deTechnische Universiteit Eindhoven, op gezag van derector magnificus, prof.dr.ir. C.J. van Duijn, voor eencommissie aangewezen door het College voorPromoties in het openbaar te verdedigenop maandag 11 november 2013 om 16.00 uurdoorJoachim Jacob Artsgeboren te Eindhoven
Dit proefschrift is goedgekeurd door de promotoren en de samenstelling van depromotiecommissie is als volgt:voorzitter:1e promotor:2e promotor:leden:prof.dr. A.G.L. Rommeprof.dr.ir. G.J.J.A.N. van Houtumprof.dr. A.G. de Kokprof.dr.ir. O.J. Boxmaprof.dr.ir. L.A.M. van Dongen (Universiteit Twente)prof.dr. R. Levi (Massachusetts Institute of Technology)prof.dr. S. Minner (Technische Universität München)prof.dr. C. Witteveen (Technische Universiteit Delft)
AcknowledgmentsAlthough this thesis has only one author, it is in fact the result of contributions bymany people.First I would like to thank my first promotor Geert-Jan van Houtum for his supervisionand support. He taught me the tricks of the research trade as well as how to navigatethe academic world. He made sure all the research fitted in a larger perspective whilealso helping out with details and technicalities.I would like to thank NedTrain for funding my PhD research. Working in themaintenance development department of NedTrain under the supervision of BobHuisman was a great pleasure. Bob Huisman created the perfect environment wherepractice and research could meet. Apart from being involved with the particularsof research, he also has a keen eye for the human aspect of the research endeavor.I also thank Michel Wilson and Jorge Parada for our joint discussions on researchand applications at NedTrain. I thank Leo van Dongen for leading this collaborationbetween NedTrain and academia, and for chairing the steering committee of thiscollaboration. I also thank him for his input during meetings of the steering committeeand for being on my thesis committee.At NedTrain, I am also indebted to Joost Florie and Guido Aerts for their input onmodeling issues and for acquainting me with the particulars of NedTrain’s supplychain and repair shop operations.I thank Maarten Driessen for our collaboration on Chapter 2 of this thesis. I enjoyedour many conversations on how to apply scientific knowledge in practice. I also thankKristina Sharypova for tolerating such lengthy conversations in our office, bringing apleasant atmosphere to the office, and reminding us of the more important things inlife.I would like to thank Simme Douwe Flapper for our collaboration on Chapter 3.Chapter 3 has also benefited from the graduation projects of Karin Vernooij, AnneBasten, and Martine Rousseau.I thank Rob Basten for being my daily supervisor when he was in Eindhoven and hiscontributions to Chapter 4 of this thesis. Rob Basten, together with Frank Karstenand Willem van Jaarsveld, have provided the necessary feedback and reflection onacademic life.Chapter 5 of this thesis has benefited from the master thesis projects of Martijn vanAspert and Nadine Loeffen.I would like to thank Retsef Levi for hosting my visit to MIT and our joint work
on Chapter 6 of this thesis. In his busy schedule, he managed to free time for ourcollaboration and he was always very sharp during our meetings. Working at theOperations Research Center at MIT was truly stimulating. I would also like to thankmy sister Saskia and her husband John for letting me and my family stay at theirhome and otherwise making our stay in the greater Boston area a pleasant experience.My visit to MIT was partially funded by the Prins Bernhard Fellowship supportedby the De Breed Kreiken innovation fund.Ton de Kok became my second promotor somewhat late in my PhD project, but hasshown an active interest in my work from the beginning. I really enjoyed our manyconversations on very diverse topics.I thank Onno Boxma, Stefan Minner, and Cees Witteveen for being on my thesiscommittee and their valuable feedback on my work.Qiushi Zhu was my office mate for almost three years. We had some great laughs andhe was always patient enough to hear the boring details of my research problems.I thank all my current and former colleagues at the OPAC department for the goodatmosphere and tea breaks. In particular, Claudine made for an excellent atmospherein the E-corridor and she helped with many planning en technical problems (in thenon-mathematical sense).When I was young, my parents taught me the value of getting a good education. Ithank them for supporting me all the way to a PhD degree. My siblings were veryinfluential in shaping my ideas about the quest for truth and the role of academicresearch in this quest.Doing a PhD can put quite some strain on family life and I thank my wife Heidi forsupporting me in ways too numerous to mention. She performed a very thoroughproofreading of the entire thesis and carefully checked my algebra when I was doing along derivation and needed a second pair of eyes. My two sons were also instrumentalin the moral support needed to complete a thesis. They make a short appearance inChapter 5.Finally, I thank my Father in heaven for his support in all things.
Contents1 Introduction1.1 Maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.1 Maintenance strategies . . . . . . . . . . . . . . . . . . . . . . .1.1.2 Uncertainty in maintenance operations . . . . . . . . . . . . . .1.1.3 Spare parts in maintenance operations . . . . . . . . . . . . . .1.1.4 Maintenance operations at NedTrain . . . . . . . . . . . . . . .1.2 Spare part supply chains . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.1 Repair and overhaul shops . . . . . . . . . . . . . . . . . . . . .1.2.2 Performance measures . . . . . . . . . . . . . . . . . . . . . . .1.2.3 Spare part supply chain at NedTrain . . . . . . . . . . . . . . .1.3 Research objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.1 Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.2 Rotables, usage based maintenance and efficient utilization ofresources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.3 Repairables, condition based maintenance, and repair lead timeflexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.4 Consumables, emergency procedures . . . . . . . . . . . . . . .1.4 Contributions of the thesis . . . . . . . . . . . . . . . . . . . . . . . . .1.4.1 Rotable overhaul planning . . . . . . . . . . . . . . . . . . . . .1.4.2 Repairable stocking and expediting under fluctuating demand .1.4.3 Consumable stocking with emergency shipments . . . . . . . .1.5 Outline of the thesis . . . . . . . . . . . . . . . . . . . . . . . . . . . .131414141618192 Maintenance spare parts planning framework2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Characterization of the environment . . . . . . . . . . . . . .2.2.1 Characterization of system maintenance . . . . . . . .2.2.2 Maintenance spare parts supply chain overview . . . .2.2.3 Demand characteristics of maintenance spare parts . .2.3 Framework for maintenance spare parts planning and control2.3.1 Assortment management . . . . . . . . . . . . . . . . .2121242426282829.1446799101111121212
2.42.52.3.2 Demand forecasting . . . . . . . . . . .2.3.3 Parts returns forecasting . . . . . . . . .2.3.4 Supply management . . . . . . . . . . .2.3.5 Repair shop control . . . . . . . . . . .2.3.6 Inventory control . . . . . . . . . . . . .2.3.7 Spare parts order handling . . . . . . .2.3.8 Deployment . . . . . . . . . . . . . . . .Framework related literature and open research2.4.1 Assortment management literature . . .2.4.2 Demand forecasting literature . . . . . .2.4.3 Parts returns forecasting literature . . .2.4.4 Supply management literature . . . . .2.4.5 Repair shop control literature . . . . . .2.4.6 Inventory control literature . . . . . . .2.4.7 Spare parts order handling literature . .2.4.8 Literature overview . . . . . . . . . . . .Concluding remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .topics. . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Rotable overhaul and supply chain planning3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Literature review and contribution . . . . . . . . . . . .3.2.1 Preventive maintenance and capacity planning .3.2.2 Aggregate production and supply chain planning3.2.3 Contribution . . . . . . . . . . . . . . . . . . . .3.3 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.1 Supply chain dynamics . . . . . . . . . . . . . . .3.3.2 Workforce capacity and flexibility in the overhaul3.3.3 Rotable availability . . . . . . . . . . . . . . . . .3.3.4 Overhaul deadlines propagation . . . . . . . . . .3.3.5 Cost factors . . . . . . . . . . . . . . . . . . . . .3.3.6 Model remarks . . . . . . . . . . . . . . . . . . .3.3.7 Mixed integer programming formulation . . . . .3.3.8 Modeling flexibility . . . . . . . . . . . . . . . . .3.4 Case study . . . . . . . . . . . . . . . . . . . . . . . . .3.4.1 Computational feasibility . . . . . . . . . . . . .3.4.2 Sensitivity of result to integrality constraints . .3.4.3 Insights from case-study . . . . . . . . . . . . . .3.5 Numerical results for randomly generated instances . . .3.5.1 Random instance generator . . . . . . . . . . . .3.5.2 Results . . . . . . . . . . . . . . . . . . . . . . .3.6 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .workshop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60626363646567686970717375757780
3.A Proof of Proposition 3.2 . . . . . . . . . .3.B Details on the random instance generator3.B.1 Rotable characteristics . . . . . . .3.B.2 Initial conditions and flexibility . .3.B.3 Costs parameters . . . . . . . . . .81828283834 Repairable stocking and expediting4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Literature review . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Model formulation . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.1 Main assumptions and justifications . . . . . . . . . . . . .4.4 Exact Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.1 Expediting policy optimization . . . . . . . . . . . . . . . .4.4.2 Turn-around stock optimization . . . . . . . . . . . . . . . .4.5 E-WDT Heuristic . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5.1 World driven threshold policies . . . . . . . . . . . . . . . .4.5.2 Heuristic optimization of the turn-around stock:The E-WDT heuristic . . . . . . . . . . . . . . . . . . . . .4.6 Numerical results . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.6.1 Test bed and set-up . . . . . . . . . . . . . . . . . . . . . .4.6.2 Performance of the WDT policy for fixed turn-around stock4.6.3 Performance of the E-WDT heuristic . . . . . . . . . . . . .4.6.4 Value of anticipating demand fluctuations . . . . . . . . . .4.7 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .y4.A Determining P{Dt,t k} . . . . . . . . . . . . . . . . . . . . . .e4.B Proofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.B.1 Proof of Lemma 4.1 . . . . . . . . . . . . . . . . . . . . . .4.B.2 Proof of Proposition 4.1 (ii) . . . . . . . . . . . . . . . . . .4.B.3 Proof of Lemma 4.2 . . . . . . . . . . . . . . . . . . . . . .4.B.4 Proof of Lemma 4.4 . . . . . . . . . . . . . . . . . . . . . .85. 85. 89. 90. 92. 94. 94. 104. 107. 108.1101111111131151161181201211211211241265 A system approach to repairable stocking and expediting5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . .5.2 Literature review and contribution . . . . . . . . . . .5.2.1 Fluctuating demand . . . . . . . . . . . . . . .5.2.2 Expediting and repair scheduling policies . . .5.2.3 Decomposition and column generation . . . . .5.3 Model . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.1 Notation and preliminaries . . . . . . . . . . .5.3.2 Control policy . . . . . . . . . . . . . . . . . .5.3.3 Markov Modulated demand models and fitting.129129131131132133134134136139.
5.3.4 Optimization problem . . . . . . . . . . . . . . . .Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4.1 Constructing lower bounds with column generation5.4.2 Constructing a good feasible solution . . . . . . . .5.5 Computational results . . . . . . . . . . . . . . . . . . . .5.5.1 Objectives and test bed . . . . . . . . . . . . . . .5.5.2 Results . . . . . . . . . . . . . . . . . . . . . . . .5.6 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . .5.A Proof of Proposition 5.1 . . . . . . . . . . . . . . . . . . .5.46 Base-stock policies for consumables6.1 Introduction . . . . . . . . . . . . . . . . . . . .6.2 Model . . . . . . . . . . . . . . . . . . . . . . .6.3 State space aggregation . . . . . . . . . . . . .6.4 Asymptotics . . . . . . . . . . . . . . . . . . . .6.5 Rates of convergence . . . . . . . . . . . . . . .6.6 Internal consistency: flow conservation . . . . .6.7 Extensions . . . . . . . . . . . . . . . . . . . . .6.7.1 General single period cost functions . .6.7.2 Service level constraints . . . . . . . . .6.8 Numerical results . . . . . . . . . . . . . . . . .6.9 Conclusion . . . . . . . . . . . . . . . . . . . .6.A Proofs . . . . . . . . . . . . . . . . . . . . . . .6.A.1 Proof of Proposition 6.1 . . . . . . . . .6.A.2 Proof of Theorem 6.4 . . . . . . . . . .6.A.3 Derivation of the state space size of Qt6.B The generalized Pareto distribution . . . . . . .6.C Tables with details per instance . . . . . . . . 1691691691701761771771781791791807 Conclusion7.1 Research objectives revisited . . . . . . . . . . . . . . . . . . . . . . .7.1.1 Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1.2 Rotables, usage based maintenance and efficient utilization ofresources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1.3 Repairables, condition based maintenance, and repair lead timeflexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1.4 Consumables, emergency procedures . . . . . . . . . . . . . . .193193193Bibliography197Summary211194195196
About the author217
Chapter 1Introduction“The whole is more than the sumof its parts”AristotleInterchangeable parts have revolutionized modern manufacturing. Before the industrial revolution, products were made one-by-one as a whole in workshops by craftsmen.After the industrial revolution and up until today, most products are assembledfrom interchangeable parts. Recent research identifies the French General JeanBaptiste de Gribeauval as the principal originator of working with interchangeableparts (Hounshell, 1984). He introduced a system for constructing French artillery frominterchangeable parts in 1765. His system became known as “le système Gribeauval”.Thomas Jefferson1 was introduced to le système Gribeauval in 1785 when he was inFrance as a diplomat, and visited the weapon workshop of Honeré Blanc who wasa gunsmith implementing le système Gribeauval. In a letter to John Jay2 , ThomasJefferson wrote about this visit:An improvement is made here in the construction of the musket which itmay be interesting to Congress to know, should they at any time proposeto procure any. It consists in the making every part of them so exactlyalike that what belongs to any one may be used for any other musketin the magazine. The government here has examined and approved the1 ThomasJefferson (1743-1826) is a founding father of the United States of America, its thirdpresident, and one of the principal authors of the declaration of independence.2 John Jay (1745-1829) is a founding father of the United States of America and the first ChiefJustice of the United States
2Chapter 1. Introductionmethod, and is establishing a large manufactory for this purpose. As yetthe inventor3 has only completed the lock of the musket on this plan. Hewill proceed immediately to have the barrel, stock and their parts executedin the same way. Supposing it might be useful to the U.S. I went to theworkman. He presented me with th
Spare parts planning and control for maintenance operations Citation for published version (APA): Arts, J. J. (2013). Spare parts planning and control for maintenance operations. . Operations Management and Logistics. The Beta Research School is a joint e ort of the School of Industrial Engineering and the department of Mathematics and
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