A Multi-Stage Two-Machines Replacement Strategy Using Mixture Models, Bayesian Inference, and Stochastic Dynamic Programming

If at least one out of two serial machines that produce a specific product in manufacturing environments malfunctions, there will be non conforming items produced. Determining the optimal time of the machines' maintenance is the one of major concerns. While a convenient common practice for this kind of problem is to fit a single probability distribution to the combined defect data, it does not adequately capture the fact that there are two different underlying causes of failures. A better approach is to view the defects as arising from a mixture population: one due to the first machine failures and the other due to the second one. In this article, a mixture model along with both Bayesian inference and stochastic dynamic programming approaches are used to find the multi-stage optimal replacement strategy. Using the posterior probability of the machines to be in state λ1, λ2 (the failure rates of defective items produced by machine 1 and 2, respectively), we first formulate the problem as a stochastic dynamic programming model. Then, we derive some properties for the optimal value of the objective function and propose a solution algorithm. At the end, the application of the proposed methodology is demonstrated by a numerical example and an error analysis is performed to evaluate the performances of the proposed procedure. The results of this analysis show that the proposed method performs satisfactorily when a different number of observations on the times between productions of defective products is available.