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E-grāmata: Warranty and Preventive Maintenance for Remanufactured Products: Modeling and Analysis

(Northeastern University, Boston, USA), (King Abdulaziz University, Makkah, Saudi Arabia)
  • Formāts: 340 pages
  • Izdošanas datums: 12-Dec-2018
  • Izdevniecība: CRC Press
  • Valoda: eng
  • ISBN-13: 9781351599207
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Warranty and Preventive Maintenance for Remanufactured Products: Modeling and AnalysisPalielināt
  • Formāts: 340 pages
  • Izdošanas datums: 12-Dec-2018
  • Izdevniecība: CRC Press
  • Valoda: eng
  • ISBN-13: 9781351599207
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The exponential increase in the development of technology coupled with the customers immense desire to possess the newest technological products makes for truncated product lifespans, which instigates a substantial upsurge in their rate of disposal. Attempts have been made to establish specialized product recovery facilities with the intention of diminishing the volume of accumulated waste delivered to landfills using product recovery procedure such as remanufacturing. The economic benefits produced by remanufacturing also portray the role of product recovery in a more attractive light.

The quality of a remanufactured product is uncertain for some consumers. Therefore, these consumers possess insecurities in deciding whether or not the remanufactured products will render the same expected performance. This ambiguity regarding a remanufactured product could possibly result in the consumer deciding against its purchase. With such consumer apprehension, remanufacturers often seek market mechanisms that provide reassurance as to the stable durability that these products still maintain. One strategy that the remanufacturers often use is the utilization of the premise of offering product warranties with preventive maintenance on their products.

This book is concerned with the practice and theory of warranty management and preventive maintenance, particularly in relation to remanufactured products warranties. Models developed in this book can be used for making the right decisions in offering renewable, nonrenewable, one and two dimensional warranty policies, and for managerial decision in considering maintenance contracts or outsourcing maintenance for remanufactured components and products.

Features











Discusses a variety of warranty policies and preventive maintenance of remanufactured products (first book to do so) Presents mathematical models and applications for warranty policies using examples and simulation results Considers cost and optimization problems from the remanufacturer's and buyer's points of views Provides a foundation for academicians interested in building models in the area of warranty and preventive maintenance analysis of remanufactured products Offers the essential methodology needed by practitioners involved with warranty and preventive maintenance analysis, along with extensive references for further research
List of Figures xv
List of Tables xvii
Preface xxv
Acknowledgments xxix
Authors xxxi
List of Notations xxxiii
Acronyms xxxvii
1 Introduction and Overview 1(4)
1.1 Overview
1(1)
1.2 Motivation
2(1)
1.3 Scope and Contribution of this Book
2(1)
1.4 Outline of the Book
3(2)
2 Review of Product Recovery, Sensor-Embedded Products, Warranty and Maintainability 5(34)
2.1 Environmentally Conscious Manufacturing and Product Recovery (ECMPRO)
5(20)
2.1.1 Reverse and Closed-Loop Supply Chains
8(2)
2.1.2 Product Recovery
10(7)
2.1.2.1 Disassembly
11(2)
2.1.2.2 Reuse
13(1)
2.1.2.3 Remanufacturing
13(4)
2.1.2.4 Recycling
17(1)
2.1.3 Product Design
17(30)
2.1.3.1 Design for X
18(3)
2.1.3.2 Life-Cycle Assessment
21(3)
2.1.3.3 Material Selection
24(1)
2.2 Sensor-Embedded Products
25(1)
2.3 Warranty Analysis
26(6)
2.4 Maintenance Analysis
32(5)
2.5 Conclusions
37(2)
3 Product Warranty and Preventive Maintenance 39(6)
3.1 Introduction
39(1)
3.2 The Problem Statement
40(1)
3.3 Definitions of Warranty
41(1)
3.4 Warranties for Remanufactured Products
41(1)
3.5 Preventive Maintenance for Remanufactured Products
42(2)
3.6 Objectives of the Book
44(1)
4 Warranty Policies for Remanufactured Products with Preventive Maintenance Strategy 45(18)
4.1 Introduction
45(1)
4.2 Sensor-Embedded Remanufactured Product
46(1)
4.3 Classification of Warranty Policies
47(2)
Notations
48(1)
4.4 Simple Warranty Policies for Remanufactured Products (Group 1)
49(1)
4.4.1 Free-Replacement Warranty Policy (FRW)
49(1)
4.4.2 Pro-Rata Warranty Policy (PRW)
49(1)
4.5 Simple Warranty Policies for Remanufactured Products (Group 2)
49(2)
4.5.1 Cost-Sharing Warranty (CSW) Policies
49(1)
4.5.2 Cost-Limit Warranty (CLW) Policies
50(1)
4.5.3 Buyback Warranty (BBW) Policies
50(1)
4.6 Combination Policies for Remanufactured Products
51(2)
4.6.1 FRW-PRW Combination Policy
51(1)
4.6.2 Combination Policies with Cost-Limit Warranty (CLW)
51(1)
4.6.3 Combination Policies with Cost-Sharing Warranty (CSW)
52(1)
4.6.4 Combination Policies with Buyback Warranty Policies (BBW)
52(1)
4.7 Renewable Policies
53(1)
4.8 Two-Dimensional Warranty Policies for Remanufactured Products
53(5)
4.8.1 Simple Two-Dimensional Warranty
53(3)
4.8.2 Combination Two-Dimensional Warranties
56(2)
4.9 Maintenance Strategies for Remanufactured Products
58(3)
4.10 Conclusions
61(2)
5 Modeling Warranty Costs with Preventive Maintenance for Remanufactured Products 63(28)
5.1 Introduction
63(1)
5.2 Modeling the Failures of Remanufactured Products
64(4)
Notations
65(3)
5.3 Modeling Preventive Maintenance and Its Effect
68(1)
5.4 Modeling Failures at System Level
69(6)
5.4.1 Model S1 (SEPs with Corrective Maintenance)
69(1)
5.4.2 Model S2 (Conventional Remanufactured Product with Corrective Maintenance)
70(2)
5.4.3 Model S3 (SEPs with Preventive Maintenance)
72(2)
5.4.3.1 Method 1: Using Binary Random Variable
73(1)
5.4.3.2 Method 2: Using Different Intensity Functions
74(1)
5.4.4 Model S4 (Conventional Product with Preventive and Corrective Maintenance)
74(1)
5.4.4.1 Method 1: Using Binary Random Variable
75(1)
5.4.4.2 Method 2: Using Different Intensity Functions
75(1)
5.5 Modeling Failures at Component Level
75(11)
5.5.1 First Failure
76(1)
5.5.2 Succeeding Failures
76(1)
5.5.3 Model C1 (Sensor-Embedded Component, Non-Repairable, Replace by New)
77(1)
5.5.3.1 First Failure of Non-Repairable Sensor-Embedded Component
77(1)
5.5.3.2 Succeeding Failures of Non-Repairable Sensor-Embedded Component
78(1)
5.5.4 Model C2 (Conventional Components, Non-Repairable, Replace by New)
78(2)
5.5.4.1 First Failure of Non-Repairable Conventional Component
79(1)
5.5.4.2 Succeeding Failures of Non-Repairable Conventional Component
79(1)
5.5.5 Model C3 (Sensor-Embedded Component, Non-Repairable, Replace by Remanufactured)
80(1)
5.5.5.1 First Failure of Non-Repairable Sensor-Embedded Component
80(1)
5.5.5.2 Succeeding Failures of Non-Repairable Sensor-Embedded Component
80(1)
5.5.6 Model C4 (Conventional Components, Non-Repairable, Replace by Remanufactured)
81(1)
5.5.6.1 First Failure of Non-Repairable Conventional Component
82(1)
5.5.6.2 Succeeding Failures of Non-Repairable Conventional Component
82(1)
5.5.7 Model C5 (Sensor-Embedded Component, Repairable with Corrective Maintenance)
82(1)
5.5.8 Model C6 (Conventional Components, Repairable with Corrective Maintenance)
83(1)
5.5.9 Model C7 (Sensor-Embedded Component, Repairable with Preventive Maintenance)
84(1)
5.5.9.1 First Failure of Repairable Sensor-Embedded Component
84(1)
5.5.9.2 Succeeding Failures of Repairable Sensor-Embedded Component
85(1)
5.5.10 Model C8 (Conventional Product, Repairable with Preventive Maintenance)
85(1)
5.5.10.1 First Failure of Repairable Sensor-Embedded Component
86(1)
5.5.10.2 Succeeding Failures of Repairable Sensor-Embedded Component
86(1)
5.6 Costs of Warranty
86(2)
5.6.1 Replacement/Repair Cost
86(1)
5.6.2 Cost of Repair at System Level
87(1)
5.6.3 Cost of Repair at Component Level
87(1)
5.7 Costs of Maintenance
88(1)
5.7.1 Cost of Each Preventive Maintenance
88(1)
5.7.2 Cost of Each Corrective Maintenance
89(1)
5.8 Conclusions
89(2)
6 Representative Remanufacturing Facility Used for the Analysis of Warranty and Preventive Maintenance 91(20)
6.1 Introduction
91(1)
6.2 System Description
92(9)
6.2.1 Advanced Remanufacture-to-Order System
92(16)
6.2.1.1 Products Arrivals
93(4)
6.2.1.2 Preventive Maintenance Arrival
97(3)
6.2.1.3 Warranty Claims Arrival
100(1)
6.3 Design-of-Experiments Study
101(7)
6.4 Parameter Values for Warranty Cost Analysis
108(1)
6.4.1 Data Set I: (System Level Modeling)
108(1)
6.4.2 Data Set II: (Component Level Modeling)
108(1)
6.5 Conclusions
109(2)
7 Cost Analysis of Simple Non-Renewing Warranties - Group 1 111(44)
7.1 Introduction
111(1)
7.2 Some Preliminaries
111(2)
7.2.1 Assumptions
112(1)
7.2.2 Notations
112(1)
7.2.3 Parameter Values for Numerical Examples
113(1)
7.3 Analysis of Free-Replacement Warranty Policy
113(33)
7.3.1 FRW for Model 51 (SEPs, Corrective Maintenance)
113(2)
7.3.2 FRW for Model S2 (Conventional Product, Corrective Maintenance)
115(4)
7.3.2.1 Pricing of Remanufactured Item
117(2)
7.3.3 FRW for Model S3 (SEPs, Preventive Maintenance)
119(1)
7.3.4 FRW for Model S4 (CPs, Preventive Maintenance)
120(2)
7.3.5 Model C1 (Sensor-Embedded Components, Non-Repairable, Corrective Maintenance, Replacement by New)
122(5)
7.3.6 Model C2 (Conventional Component, Non-Repairable, Corrective Maintenance, Replacement by New)
127(1)
7.3.7 Model C3 (Sensor-Embedded Component, Non-Repairable, Preventive Maintenance, Replace by Remanufactured)
127(4)
7.3.8 Model C4 (Conventional Component, Non-Repairable, Preventive Maintenance, Replacement by Remanufactured)
131(2)
7.3.9 Model C5 (Sensor-Embedded Component, Minimal Repair with Corrective Maintenance)
133(4)
7.3.10 Model C6 (Conventional Component, Minimal Repair with Corrective Maintenance)
137(1)
7.3.11 Model C7 (Sensor-Embedded Component, Imperfect Repair with Preventive Maintenance)
137(1)
7.3.12 Model C8 (Conventional Component, Imperfect Repair with Preventive Maintenance)
138(1)
7.3.13 FRW Summary Results
139(7)
7.3.13.1 Effect of SEPs on FRW Warranty Policy
141(5)
7.4 Analysis of Pro-Rata Warranty Policy
146(8)
7.4.1 Model Cl (Sensor-Embedded Components, Non-Repairable, Corrective Maintenance, Replacement by New)
149(1)
7.4.2 PRW Summary Results
150(6)
7.4.2.1 Effect of SEPs on PRW Warranty Policy
153(1)
7.5 Conclusions
154(1)
8 Cost Analysis of Simple Non-Renewing Warranties - Group 2 155(32)
8.1 Introduction
155(1)
8.2 Some Preliminaries
156(1)
8.3 Analysis of Specified Parts Excluded Policy
156(9)
8.3.1 Model S3 (SEPs, Preventive Maintenance)
156(3)
8.3.1.1 Method 1: Binary Random Variable
156(3)
8.3.1.2 Method 2: Different Intensity Function
159(1)
8.3.2 Model S4 (CPs, Preventive Maintenance)
159(6)
8.3.2.1 Method 1: Binary Random Variable
161(3)
8.3.2.2 Method 2: Different Intensity Function
164(1)
8.4 Analysis of Lump-Sum Cost-Sharing Policy
165(5)
8.4.1 Model S1 (Sensor-Embedded, Corrective Maintenance)
165(2)
8.4.2 Model S2 (Conventional Product, Corrective Maintenance)
167(1)
8.4.3 Model S3 (SEPs, Preventive Maintenance)
168(1)
8.4.4 Model S4 (Conventional Product, Preventive Maintenance)
169(1)
8.5 Analysis of Labor/Material Cost-Sharing Policy
170(3)
8.5.1 Model S3 (SEPs, Preventive Maintenance)
170(1)
8.5.2 Model S4 (CPs, Preventive Maintenance)
171(2)
8.6 Analysis of Limit on Individual Cost Policy
173(2)
8.6.1 Model S3 (SEPs, Preventive Maintenance)
173(1)
8.6.2 Model S4 (CPs, Preventive Maintenance)
174(1)
8.7 Analysis of Individual Cost Deductible Policy
175(3)
8.7.1 Model S3 (SEPs, Preventive Maintenance)
176(1)
8.7.2 Model S4 (CPs, Preventive Maintenance)
177(1)
8.8 Analysis of Limit on Total Cost Policy
178(3)
8.8.1 Model S3 (SEPs, Preventive Maintenance)
179(1)
8.8.2 Model S4 (CPs, Preventive Maintenance)
180(1)
8.9 Analysis of Total Cost Deductibles Policy
181(3)
8.9.1 Model S3 (SEPs, Preventive Maintenance)
182(1)
8.9.2 Model S4 (CPs, Preventive Maintenance)
183(1)
8.10 Analysis of Money-Back Guarantee Policy
184(2)
8.10.1 Model S1 (SEPs, Minimal Repair, Corrective Maintenance)
185(1)
8.11 Conclusions
186(1)
9 Cost Analysis of Combination Warranties 187(38)
9.1 Introduction
187(1)
9.2 Some Preliminaries
188(1)
9.2.1 Notations
188(1)
9.2.2 Parameter Values for Numerical Examples
189(1)
9.3 Analysis of the FRW-PRW Combination Policy
189(7)
9.3.1 Model C3 (Sensor-Embedded Component, Non-Repairable, Replacement by Remanufactured)
189(3)
9.3.2 Model C4 (Conventional Component, Replacement by Remanufactured)
192(4)
9.4 Analysis of the Limits on Individual and Total Cost Policy
196(5)
9.4.1 Model S3 (SEPs, Preventive Maintenance)
197(1)
9.4.2 Model S4 (CPs, Preventive Maintenance)
198(3)
9.5 Analysis of the FRW-LIC Combination Policy
201(3)
9.5.1 Model S3 (SEPs, Preventive Maintenance)
201(2)
9.5.2 Model S4 (CPs, Preventive Maintenance)
203(1)
9.6 Analysis of the FRW-LCS Combination Policy
204(3)
9.6.1 Model S3 (SEPs, Preventive Maintenance)
204(1)
9.6.2 Model S4 (CPs, Preventive Maintenance)
205(2)
9.7 Analysis of the FRW-LMS Combination Policy
207(3)
9.7.1 Model S3 (SEPs, Preventive Maintenance)
207(1)
9.7.2 Model S4 (CPs, Preventive Maintenance)
208(2)
9.8 Analysis of MBG-FRW Combination Policy
210(2)
9.8.1 Model S3 (SEPs, Preventive Maintenance)
210(2)
9.9 Analysis of the MBG-PRW Combination Policy
212(1)
9.10 Analysis of the MBG-LIC Combination Policy
213(4)
9.10.1 Model S3 (SEPs, Preventive Maintenance)
215(2)
9.10.1.1 Remanufacturer's Expected Cost
215(1)
9.10.1.2 Buyer's Expected Cost
216(1)
9.11 Analysis of the MBG-LITC Combination Policy
217(6)
9.11.1 Model S3 (SEPs, Preventive Maintenance)
218(7)
9.11.1.1 Remanufacturer's Expected Cost
219(1)
9.11.1.2 Buyer's Expected Cost
220(3)
9.12 Conclusions
223(2)
10 Cost Analysis of Renewing Warranties 225(16)
10.1 Introduction
225(1)
10.2 Preliminaries
225(1)
10.2.1 Notations
226(1)
10.3 Analysis of the Renewing Free-Replacement Warranty Policy
226(3)
10.3.1 Model C3 (Sensor-Embedded Component, Non-Repairable, Replacement by Remanufactured)
226(3)
10.3.2 Model C4 (Conventional Component, Non- Repairable, Replacement by Remanufactured)
229(1)
10.4 Analysis of the Renewing Pro-Rata Warranty Policy
229(3)
10.4.1 Model C3 (Sensor-Embedded Component, Non-Repairable, Replacement by Remanufactured)
230(2)
10.5 Analysis of the Renewing Combination RFRW-RPRW Warranty Policy
232(1)
10.6 Summary Analysis of Renewing Warranty Policies
233(6)
10.7 Conclusions
239(2)
11 Cost Analysis of Two-Dimensional Warranties 241(28)
11.1 Introduction
241(1)
11.2 Two-Dimensional Warranty
241(25)
11.2.1 Analysis of Two-Dimensional FRW Policies
241(11)
11.2.1.1 Analysis of Two-Dimensional Non-Renewing FRW Policies
243(5)
11.2.1.2 Analysis of Two-Dimensional Renewing FRW Policies
248(4)
11.2.2 Analysis of Two-Dimensional PRW Policies
252(6)
11.2.2.1 Analysis of Two-Dimensional Non-Renewing PRW Policies
252(4)
11.2.2.2 Analysis of Two-Dimensional RPRW Policies
256(2)
11.2.3 Analysis of Two-Dimensional Combination Warranties
258(8)
11.2.3.1 Analysis of Two-Dimensional Non-Renewing FRW-PRW Policy
260(3)
11.2.3.2 Analysis of Two-Dimensional Renewing FRW-PRW Policy
263(3)
11.3 Conclusions
266(3)
12 Conclusion 269(2)
References 271(18)
Author Index 289(6)
Subject Index 295
Ammar Y. Alqahtani, Ph.D., is an Assistant Professor of Industrial Engineering at King Abdulaziz University in Jeddah, Saudi Arabia. He received his BS degree with first honors from the Industrial Engineering Department of King Abdulaziz University, Jeddah, Saudi Arabia, in May 2008. Being awarded with a full scholarship by the King Abdulaziz University (KAU), he received his MS degree in Industrial Engineering from Cullen College of Engineering, University of Houston in 2012. He received his PhD degree in Industrial Engineering from Northeastern University, Boston, in 2017. He has been employed as a faculty member by King Abdulaziz University since December 2008. His research interests are in the areas of environmentally conscious manufacturing, product recovery, reverse logistics, closed-loop supply chains (CLSC), sustainable operations and sustainability, simulation and statistical analysis and modeling with applications in CLSC and multiple lifecycle products. He has co-authored several technical papers published in edited books, journals and international conference proceedings.

Surendra M. Gupta, Ph.D., is a Professor of Mechanical and Industrial Engineering and the Director of the Laboratory for Responsible Manufacturing at Northeastern University in Boston, Massachusetts, USA. He received his BE in Electronics Engineering from Birla Institute of Technology and Science, MBA from Bryant University, and MSIE and Ph.D. in Industrial Engineering from Purdue University. He is a registered professional engineer in the State of Massachusetts, USA. Dr. Guptas research interests span the areas of Production/Manufacturing Systems and Operations Research. He is mostly interested in Environmentally Conscious Manufacturing, Reverse and Closed-Loop Supply Chains, Disassembly Modeling and Remanufacturing. He has authored or coauthored twelve books and approximately 600 technical papers published in edited books, journals and international conference proceedings. His publications have received over 11,700 citations (with an h-index of 53) from researchers all over the world in journals, proceedings, books, and dissertations. He has traveled to all seven continents viz., Africa, Antarctica, Asia, Australia, Europe, North America and South America and presented his work at international conferences on six continents. Dr. Gupta has taught over 150 courses in such areas as operations research, inventory theory, queuing theory, engineering economy, supply chain management, and production planning and control. Among the many recognitions received, he is the recipient of outstanding research award and outstanding industrial engineering professor award (in recognition of teaching excellence) from Northeastern University as well as a national outstanding doctoral dissertation advisor award.
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