A Combinatorial Approach To Level of Repair Analysis
A Combinatorial Approach To Level of Repair Analysis
www.elsevier.com/locate/dsw
Abstract
This paper presents an approach to optimise level of repair decisions taking into account submodular properties of
standard life cycle cost functions, which include ®xed and variable costs. It proposes an integer programming for-
mulation to solve level of repair problems for multi-echelon multi-indenture level systems. The method converges
quickly to the optimum solution relying on heuristics to obtain tight bounds for a subsequent branch-and-bound
procedure. A software package called level of repair optimisation model (LOROM) was developed to implement the
branch-and-bound method that does not rely on linear programming relaxations. This approach is rather generic and
can be applied to a wide class of problems with convex total cost functions such as plant location problems or
transportation problems with ®xed costs. Ó 2001 Elsevier Science B.V. All rights reserved.
Keywords: Combinatorial optimisation; Integer programming; Logistics; Submodular functions; Repair policy
0377-2217/01/$ - see front matter Ó 2001 Elsevier Science B.V. All rights reserved.
PII: S 0 3 7 7 - 2 2 1 7 ( 0 0 ) 0 0 2 2 1 - 6
L. Barros, M. Riley / European Journal of Operational Research 129 (2001) 242±251 243
(iii) the algorithm only requires arithmetic sums The LORA problem can then be formulated as
and subtractions, thus being computer-time e- follows:
cient. XX XX
The problem is formulated as a multiple loca- P1 MINIMISE vcrx nrx fcri mri
tion problem with ®xed and variable costs, where r2R x2X r2R1 i2I
preserved after many types of operations and above, a positive real-value marginal cost function
transformations (Lovasz, 1983). The maximisation
MC
x can be generically de®ned as follows:
of submodular functions (equivalent to the mini-
misation of a supermodular function) is NP-hard MC MC
x c0 c1 x c2 x2 for x X :
(Kubiak, 1995) but the minimisation of such Or more speci®cally, using [TC],
functions is much more amenable to mathematical
treatment, in particular where greedy algorithms MC
x b1 2b2 x 3b3 x2 for x X :
can be used. Goldengorin et al. (1999) proposed an
algorithm for the NP-hard problem of minimising This function is represented graphically as a
a supermodular function that are applicable to a U-shaped curve (Varian, 1984) or a concave
wide class of problems, including transportation upward function (Nicholson, 1986), where c1 > 0
with ®xed costs and facility location problems. and c2 6 0.
Submodular functions satisfy what is known in These functions illustrate the process of starting
microeconomic theory as diminishing returns to production with little know-how so that TC in-
scale or the ``law of diminishing returns'' (Gold- creases as x increases but at decreasing rates until
engorin et al., 1999). the ®rst saddle point, where d
CT
x=d
x 0
i.e., the following inequalities hold in this region:
MC d
CT
x=d
x > 0;
6
2. The law of diminishing returns and total cost
2
functions d2
CT
x=d
x < 0:
7
The law of diminishing returns state that ``when The second saddle point, which is the one in the
units of a variable factor (e.g. labour) are added to region of interest in a cost minimisation problem is
a ®xed factor (e.g. land), the output resulting . . . reached as TC starts to decrease. In this region, the
(®rst) increases at an increasing rate, then increases ®rm becomes ecient by adding more variable
at a decreasing rate, and ®nally decrease'' (Nich- costs to ®xed resources while operating within
olson, 1986, p. 210). It causes the typical total cost capacity constraints. However, the law of dimin-
function to be cubic as a function of the output. ishing returns will cause TC to decrease at de-
The same set of reasonable assumptions about creasing rates because ®xed resources are
diminishing returns generate a typically quadratic becoming gradually more stretched. In this region,
marginal cost function. A real-valued total cost the following inequalities hold:
function de®ned over a set X for x > 0 can be MC d
CT
x=d
x < 0;
8
represented as shown below
2
d2
CT
x=d
x < 0:
9
TC TC
x b0 b1 x b2 x2 b3 x3
for x X ; Finally, after the second saddle point total costs
start to increase because ®xed resources have been
where TC is total repair cost and x X the total used to capacity and there is an eect similar to
quantity of output, b0 represents ®xed costs (which ``crowding'' of variable resources, as when too
do not vary with the output) and b3 6 0. Although many workers are ®tted within a limited size
no de®nite statements can be made about these physical plant. In this region
functions, they often have two turning points with
MC d
CT
x=d
x > 0;
10
one segment concave and another segment convex
(Nicholson, 1986, p. 209). d2
CT
x=d
x2 > 0:
11
Another concept used in the discussion below is
marginal cost de®ned as the relative changes in The region of interest for cost minimisation is
TC
x with respect to x or, in mathematical terms, when the ®rm is operating eciently within ca-
d
TC
x=d
x. Given the cubic TC function pacity constraints, i.e. inequalities (8) and (9) hold
L. Barros, M. Riley / European Journal of Operational Research 129 (2001) 242±251 245
and TC is continuous and convex (see Varian, that minimises total costs for each type of repair
1984 for more complete mathematical treatment of facility (including non-repair or discard). This
these concepts and Alfredsson, 1997 for a de®ni- approach ®ts in a wide class of operational re-
tion of ecient points). What makes these state- search problems known collectively as the facility
ments particularly interesting is the fact that location problem.
inequality (8) corresponds to the de®nition of a Tcha and Lee (1984) proposes the following
submodular function assuming TC to be a con- formulation for the multi-level uncapacitated fa-
tinuous function in the domain of interest. Poly- cility location problem. Let ciw be the pro®t asso-
nomial algorithms exist for the minimisation of ciated with satisfying the demand by client i via
submodular functions such as the objective func- facility j located at level jr 2 Jr and xiw be the
tion in [P1]. This issue is discussed further in fraction of demand by client i 2 I satis®ed by path
Section 3 below. w 2 P . Let P
jr P be the set of all possible paths
For the particular case of LORA, the output x which include facility jr and fjr be the associated
is the quantity of repair actions to be performed ®xed costs with opening such a facility. Then for
during the hardware lifetime and TC is total repair each level r there is a Boolean variable yjr such that
costs, typically calculated as the present value of
annual repair costs over the lifetime of the hard- 1 if facility j in level r is open;
yjr
ware. Total repair cost models contain ®xed and 0 otherwise:
variable costs, as discussed below. The multi-level uncapacitated facility location
problem can then be formulated as follows:
XX XX
3. LORA LOC Max ciw xiw ÿ fjr yjr
i2I w2P r2R jr 2Jr
Multi-echelon maintenance systems have at-
tracted much attention from researchers and subject to:
practitioners for the past 20 years. The ®rst broad X
xiw 1 for i 2 I;
12
literature review, now a classic reference in the w2P
®eld, is Pierskalla and Voelker (1971); Blanchard
(1986) is another classic reference in the ®eld of yjr P xiw for i 2 I; w 2 P
jr ; jr 2 Jr ; r 2 R;
13
Engineering Logistics as is Sherbrooke (1992) yjr 2 f0; 1g; jr 2 Jr ; r 2 R:
14
concerning spares inventory models. More recent
publications include Barros (1998) and Diaz and Constraint set (12) ensures that each customer
Fu (1997). is served by a single facility and the constraint set
LORA is a relatively specialised domain in this (13) ensures that such facilities are open (and thus
broad ®eld and is a design tool to help research incur ®xed costs). Constraint set (15) de®nes
and development engineers evaluate the long-term [LOC] as a mixed-integer problem. It is easy to see
impact of early design decisions on life-cycle that constraints (1), (2) and (5) in formulation [P1]
maintenance costs. Spare parts, inventory holding correspond to constraints (12), (13) and (14) in
and ordering costs, labour charges, support and formulation [LOC].
technical equipment and transportation costs are There are however, two important dierences
some important items in the evaluation of life- between these two formulations:
cycle costs (LCC). (a) The objective function in [P1] minimises total
Formulation [P1] above aggregates such costs costs (variable plus ®xed costs) while the maximi-
under two headings, ®xed and variable costs fol- sation of pro®t minus ®xed costs is the objective
lowing standard microeconomic theory as dis- function in [LOC]. The ®xed cost component in
cussed in Section 2. It deals with the decision of both formulations is exactly equivalent since
where to perform the repairs once TC (x ) has been min FC max
ÿFC. The remaining terms are
calculated, where x is the number of repair actions discussed in more detail below.
246 L. Barros, M. Riley / European Journal of Operational Research 129 (2001) 242±251
(b) Constraint sets (3) and (4) in [P1] make that If an additional facility j is added to this set, then it
problem a special case of the multi-level un- may imply an increase in ®xed costs, i.e.
capacitated problem [LOC] when there are X X
bundled commodities or clients. In other words, TC
x vcs xs fcs fcj
19
s2S s2S
some clients must be served by the same ware-
house, while others must be served by dierent and/or an increase in the volume of output for the
warehouses. It just happens that these prefer- same unit variable cost
ences are expressed across levels in [P1], for in- X X
stance if a client l is assigned to facility j in TC
x vcs xs fcs
20
level r then client m 6 I in level t 6 r must be as- s2S[fjg s2S
Replacing (16) and [TC] in (17), the resulting Proof. Submodularity means that for S Y T
equation becomes and j 2 T ÿ Y the following inequality holds (see
Benati, 1999):
P
x px
b0 b1 x b2 x2 b3 x3 ;
17
TC
S [ fjgTC
S P TC
Y [ fjgTC
Y ;
22
where b0 represents ®xed costs and
b1 x b2 x2 b3 x3 represent variable costs. The where TC(S) is de®ned as in (18). If there are only
representation of P
x as the dierence between changes in ®xed costs, then TC
S [ fjg is de®ned
total revenue and ®xed costs as used in Tcha and as in (19). Consequently
Lee (1984) is rather unusual. On the other hand,
TC
S [ fjg ÿ TC
S TC
Y [ fjgTC
Y fcj :
formulation [P1] is in agreement with standard
microeconomic theory. In addition, the maximi- If there are economies of scale, then variable costs
sation of a submodular function is a NP-hard will be dierent for the two sets of facilities and
problem, while this is not true for the minimisation vcs > vcy . Since
problem (Lovasz, 1983).
The submodularity of the objective function in TC
S [ fjg ÿ TC
S vcs xj fcj ;
[P1] can be proven using concepts such as econo-
mies of scale. Rewriting that objective function TC
Y [ fjg ÿ TC
Y vcy xj fcj ;
and specifying more clearly variable and ®xed
costs for a set of facilities S Y T and output the submodularity condition (23) holds.
x 2 X , the following equation results: The argument being put forward is that disre-
X X garding the bundling constraints for the moment,
TC
x vcs xs fcs :
18 LORA problems are a particular application of
s2S s2S the more generic multi-level uncapacitated facility
L. Barros, M. Riley / European Journal of Operational Research 129 (2001) 242±251 247
in the system, and these may run into several mri P nrx for r 2 R; i 2 I; x 2 X ;
2
thousands for a reasonably large application. The
advantage of this non-LP based branch-and- mri ; nrx 2 f0; 1g for r 2 R; i 2 I; x 2 X :
3
bound algorithm is that calculations are simple
algebraic sums and can be performed very quickly. Solve this problem by satisfying ®rst the ``eas-
As noted in Section 3, the bundling constraints iest'' constraint set (1). This is done by generating
are the most peculiar characteristic of formulation a base case tree with 2IR branches where all facili-
[P1]. These constraints force coherent repair deci- ties are initially open (mri 1 for rr 2 R and
sions across indenture levels, taking into account ri 2 I) and subsequently closed one by one until
the fact that some son components may be en- all facilities are closed (mri 0 for r 2 R and
closed into several higher indenture father com- ri 2 I). In general, not all 2IR branches need to be
ponents (a property called commonality among considered in Step 2 of the algorithm after a quick
hardware designers). Table 1 below shows six check against constraint sets (3) and (4) of the
248 L. Barros, M. Riley / European Journal of Operational Research 129 (2001) 242±251
original problem [P1]. In the case of the two- inated solutions and do not need to be examined.
indenture level two-echelon system illustrated in The recalculation of total repair costs after each
Table 1, there is no need to open any module adjustment is quite simple. Although there is no
repair facility if none are open at the subsystem guarantee that bounds will be improved during
level. Similarly, there is no need to open a local Step 3 of the algorithm, the de®nition of search
repair facility for modules if none are open for rules by infeasibility type can be rather useful in
subsystems. Step 4.
Step 2. Select least cost repair options for in- Step 4. Perform full search among the remain-
dividual system components under each base case ing base cases. Start from base case solutions,
thus respecting the ®xed cost constraints ± and which satisfy constraint sets (1) and (2) and elim-
obtain lower and upper bounds on the optimum inate infeasibilities against constraint set (3) by
solution for problem [P1]. If all facilities are open switching repair options for father±son component
at all indenture levels, then the selection of the combinations, ignoring dominated solutions. This
least cost repair option can be done by inspection. is equivalent to the depth search ®rst and then
If none are opened, then only discard is permitted back-tracking strategy described in Benati (1999).
this ± solution is necessarily feasible in [P1]. Other Real-life experience with LOROM has shown
base cases in the tree de®ne intermediate combi- that few cases are left after Steps 2 and 3 for full
natorial options between these two extremes. search and the optimum solution is quickly iden-
The overall least cost solution provides a lower ti®ed. The ratio between upper and lower bounds
bound on the optimum solution of the original and on the optimum solution tends to lie between 10%
more constrained problem [P1]. Evidently, if this and 20%, which is acceptable in many instances
lower bound is also feasible in [P1], then the op- during hardware design when cost and reliability
timum solution has to be identi®ed and there is no parameters are very imprecise. Experience has also
need to proceed to Step 3 of the algorithm. shown that the higher the ®xed costs relative to
For the upper bound, it is necessary to examine variable costs, the better the algorithm performs
base cases, which provide solutions with no pos- due to the fact that discard upon failure becomes a
sible incompatibility between father and son repair very cost-eective option.
options. These include all base cases where mri 0
for i P 1. The least cost solution among these
provides an upper bound on the optimum solution 5. An illustration: The I R 2 system
for the original problem [P1]. Evidently, if higher
and lower bounds are identical, then the optimum Fig. 1 illustrates Steps 1 and 2 of the LOROM
solution for [P1] has been identi®ed and there is no algorithm for a two-indenture two-echelon system.
need to proceed to Step 3 of the algorithm. If this The 16 branches are generated by setting mri to 1
is not the case, then the upper bound can be used and 0 at each indenture level (subsystems and
to fathom by value other base cases generated in modules). When mri 0, constraint set (2) implies
Step 1 of the algorithm. that nrx 0 for all subsystems t 2 X and all mod-
Step 3. Use a greedy heuristic algorithm to ules y 2 X . The base cases shown as INF provide
obtain tighter upper bounds on the optimum so- solutions necessarily infeasible in [P1] for any en-
lution for [P1] and cut further branches from the closed module y 2 Ct . On the other hand, base
base case decision tree which are fathomed by cases 4, 8, 10 and 11 provide solutions that are
value. The complicating bundling constraint set (3) necessarily feasible in [P1] since all modules in the
in problem [P1] are reintroduced at this step. In- system are discarded.
feasibility types can generally be de®ned by careful Step 3 requires the identi®cation of infeasibility
inspection of this constraint set and repair options types and adjustment rules for component repair
at each indenture level for sets of father and son option. In the case of I R 2 system, there are
components can be adjusted accordingly. In three possible types of infeasibilities, shown as
practice, a large number of options provide dom- blanks in Table 1:
L. Barros, M. Riley / European Journal of Operational Research 129 (2001) 242±251 249
· central repair of enclosed modules when the only three cost-increasing repair cost adjust-
subsystem is discarded, ments to eliminate this infeasibility for all
· local repair of enclosed modules when the sub- modules enclosed in a given subsystem t where
system is discarded, and y 2 Ct :
· local repair of enclosed modules when the sub- · repair the subsystem at the local facility (posture
system is repaired at the central facility. 6);
Take for example a base case solution that · discard the module (posture 1);
is infeasible in the original problem [P1] because · repair both subsystem and module at the central
of the second type of infeasibility. There are facility (posture 3).
250 L. Barros, M. Riley / European Journal of Operational Research 129 (2001) 242±251
All other alternatives listed in Table 1 provide mality at this ®nal stage also bene®ts from the
dominated solutions: repair postures 4 and 5 are special structure of the original problem that
dominated by 6, and postures 2 and 4 are domi- eliminates dominated solutions from further con-
nated by 1. Depending on the base case where the sideration. A two-indenture level two-echelon of
infeasibility under scrutiny is located, further re- maintenance system is used as an illustration for
strictions may apply. In addition, not all three the LOROM algorithm. The illustration is rather
types of infeasibilities can occur in all base cases, realistic as it accurately portraits the recommen-
further simplifying the search procedure. For in- dations in USA and UK military standard hand-
stance, the second infeasibility type can only occur, books.
where m12 1 in Fig. 1, i.e., base cases number 1, The rest of the paper argues that this type of
2, 5 and 6. problem ®ts into a more generic class of Opera-
Similar analysis for the other two types of in- tional Research problems, in particular the multi-
feasibilities can show that the ®rst type (local level uncapacitated location problem. LORA
module repair and subsystem discard) can only problems have the advantage of proposing to
occur when m11 1 in Fig. 1 as in base cases 1±8 in minimise a submodular function rather than the
Fig. 1. The third type requires m21 m12 1 and NP-hard pro®t maximisation formulation used in
can only occur in bases cases 1 and 2. In all cases, location theory. Finally, microeconomic mathe-
feasibility can be attained by examining a few cost- matical developments show theoretical links be-
increasing alternatives because other postures in tween submodularity and the law of diminishing
Table 1 provide dominated solutions or are not returns as well as economies of scale.
allowed in a particular base case.
Acknowledgements
6. Conclusions
The author wants to acknowledge the contri-
This paper presents an approach to solve multi-
bution of Dr. Mike Tso from UMIST in UK
indenture multi-echelon LORA problems based on
to this paper through useful discussions on
a branch-and-bound procedure that does not re-
submodularity and the provision of insightful
quire the use of LP relaxations. Instead, the LO-
published literature on maintenance planning.
ROM algorithm uses a relaxed version of the
original problem to create a tree with base cases,
which satisfy only the ®xed cost constraints in the
original problem. Among these cases, several so- References
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