Warranty and preventive maintenance for remanufactured products: modeling and analysis

341 Pages·2019·13.908 MB·English

by  Alqahtani, Ammar Y., Gupta, Surendra M

Warranty and Preventive
Maintenance for
Remanufactured Products
Modeling and Analysis

Warranty and Preventive
Maintenance for
Remanufactured Products
Modeling and Analysis
By
Ammar Y. Alqahtani, PhD and
Surendra M. Gupta, PhD, PE
CRC Press
Taylor & Francis Group
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Library of Congress Cataloging‑in‑Publication Data
Names: Alqahtani, Ammar Y., author. | Gupta, Surendra M., author.
Title: Warranty and preventive maintenance for remanufactured products :
modeling and analysis / Ammar Y. Alqahtani and Surendra M. Gupta.
Description: Boca Raton, FL : CRC Press/Taylor & Francis Group, 2018. |
Includes bibliographical references.
Identifiers: LCCN 2018030268| ISBN 9781138097513 (hardback : acid-free paper)
| ISBN 9781315104805 (ebook)
Subjects: LCSH: Remanufacturing--Reliability. | Recycled
products--Reliability. | Recycled products--Maintenance and repair. |
Warranty.
Classification: LCC TS183.8 .A47 2018 | DDC 363.72/82--dc23
LC record available at https://lccn.loc.gov/2018030268
Visit the Taylor & Francis Web site at
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and the CRC Press Web site at
http://www.crcpress.com
Contents
Contents
Dedicated to our families:
Nojood Alqahtani, Yahya Alqahtani, Farah Alqahtani and Lana Alqahtani
-Ammar Y. Alqahtani
Sharda Gupta, Monica Gupta, and Neil Gupta
-Surendra M. Gupta

Contents
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
1.1 Overview ................................................................................................1
1.2 Motivation ..............................................................................................2
1.3 Scope and Contribution of this Book .................................................2
1.4 Outline of the Book ...............................................................................3
2 Review of Product Recovery, Sensor-Embedded Products,
Warranty and Maintainability .....................................................................5
2.1 Environmentally Conscious Manufacturing and Product
Recovery (ECMPRO) .............................................................................5
2.1.1 Reverse and Closed-Loop Supply Chains ............................8
2.1.2 Product Recovery ...................................................................10
2.1.2.1 Disassembly ............................................................11
2.1.2.2 Reuse ........................................................................13
2.1.2.3 Remanufacturing ...................................................13
2.1.2.4 Recycling .................................................................17
2.1.3 Product Design .......................................................................17
2.1.3.1 Design for X.............................................................18
2.1.3.2 Life-Cycle Assessment ...........................................21
2.1.3.3 Material Selection ...................................................24
2.2 Sensor-Embedded Products ..............................................................25
2.3 Warranty Analysis ..............................................................................26
2.4 Maintenance Analysis ........................................................................32
2.5 Conclusions ..........................................................................................37
3 Product Warranty and Preventive Maintenance ....................................39
3.1 Introduction .........................................................................................39
3.2 The Problem Statement ......................................................................40
3.3 Definitions of Warranty .....................................................................41
3.4 Warranties for Remanufactured Products ......................................41
3.5 Preventive Maintenance for Remanufactured Products ...............42
3.6 Objectives of the Book ........................................................................44
vii
viii Contents
4 Warranty Policies for Remanufactured Products with
Preventive Maintenance Strategy .............................................................45
4.1 Introduction .........................................................................................45
4.2 Sensor-Embedded Remanufactured Product .................................46
4.3 Classification of Warranty Policies ...................................................47
Notations .........................................................................................................48
4.4 Simple Warranty Policies for Remanufactured Products
(Group 1) ...............................................................................................49
4.4.1 Free-Replacement Warranty Policy (FRW) ........................49
4.4.2 Pro-Rata Warranty Policy (PRW) .........................................49
4.5 Simple Warranty Policies for Remanufactured Products
(Group 2) ...............................................................................................49
4.5.1 Cost-Sharing Warranty (CSW) Policies...............................49
4.5.2 Cost-Limit Warranty (CLW) Policies ...................................50
4.5.3 Buyback Warranty (BBW) Policies.......................................50
4.6 Combination Policies for Remanufactured Products ....................51
4.6.1 FRW-PRW Combination Policy ............................................51
4.6.2 Combination Policies with Cost-Limit
Warranty (CLW) .....................................................................51
4.6.3 Combination Policies with Cost-Sharing Warranty
(CSW) .......................................................................................52
4.6.4 Combination Policies with Buyback Warranty
Policies (BBW) .........................................................................52
4.7 Renewable Policies ..............................................................................53
4.8 Two-Dimensional Warranty Policies for Remanufactured
Products ................................................................................................53
4.8.1 Simple Two-Dimensional Warranty ....................................53
4.8.2 Combination Two-Dimensional Warranties ......................56
4.9 Maintenance Strategies for Remanufactured Products .................58
4.10 Conclusions ..........................................................................................61
5 Modeling Warranty Costs with Preventive Maintenance for
Remanufactured Products ..........................................................................63
5.1 Introduction .........................................................................................63
5.2 Modeling the Failures of Remanufactured Products ...................64
Notations .........................................................................................................65
5.3 Modeling Preventive Maintenance and Its Effect ..........................68
5.4 Modeling Failures at System Level ...................................................69
5.4.1 Model S1 (SEPs with Corrective Maintenance) .................69
5.4.2 Model S2 (Conventional Remanufactured Product
with Corrective Maintenance) .............................................70
5.4.3 Model S3 (SEPs with Preventive Maintenance) .................72
5.4.3.1 Method 1: Using Binary Random Variable .........73
5.4.3.2 Method 2: Using Different Intensity
Functions .................................................................74
Contents ix
5.4.4 Model S4 (Conventional Product with Preventive
and Corrective Maintenance) ...............................................74
5.4.4.1 Method 1: Using Binary Random
Variable ....................................................................75
5.4.4.2 Method 2: Using Different Intensity
Functions .................................................................75
5.5 Modeling Failures at Component Level ..........................................75
5.5.1 First Failure .............................................................................76
5.5.2 Succeeding Failures ...............................................................76
5.5.3 Model C1 (Sensor-Embedded Component,
Non-Repairable, Replace by New) .......................................77
5.5.3.1 First Failure of Non-Repairable
Sensor-Embedded Component ............................77
5.5.3.2 Succeeding Failures of Non-Repairable
Sensor-Embedded Component ............................78
5.5.4 Model C2 (Conventional Components,
Non-Repairable, Replace by New) .......................................78
5.5.4.1 First Failure of Non-Repairable
Conventional Component .....................................79
5.5.4.2 Succeeding Failures of Non-Repairable
Conventional Component .....................................79
5.5.5 Model C3 (Sensor-Embedded Component,
Non-Repairable, Replace by Remanufactured) .................80
5.5.5.1 First Failure of Non-Repairable Sensor-
Embedded Component ..........................................80
5.5.5.2 Succeeding Failures of Non-Repairable
Sensor-Embedded Component ............................80
5.5.6 Model C4 (Conventional Components,
Non-Repairable, Replace by Remanufactured) .................81
5.5.6.1 First Failure of Non-Repairable
Conventional Component .....................................82
5.5.6.2 Succeeding Failures of Non-Repairable
Conventional Component .....................................82
5.5.7 Model C5 (Sensor-Embedded Component,
Repairable with Corrective Maintenance) ..........................82
5.5.8 Model C6 (Conventional Components, Repairable
with Corrective Maintenance) .............................................83
5.5.9 Model C7 (Sensor-Embedded Component,
Repairable with Preventive Maintenance) .........................84
5.5.9.1 First Failure of Repairable Sensor-
Embedded Component ..........................................84
5.5.9.2 Succeeding Failures of Repairable Sensor-
Embedded Component ..........................................85
5.5.10 Model C8 (Conventional Product, Repairable with
Preventive Maintenance) ......................................................85