An extended replacement policy for a deteriorating system with multi-failure modes

In this paper, the maintenance problem for a deteriorating system with k + 1 failure modes, including an unrepairable failure (catastrophic failure) mode and k repairable failure (non-catastrophic failure) modes, is studied. Assume that the system after repair is not “as good as new” and its deterioration is stochastic. Under these assumptions, an extended replacement policy N is considered: the system will be replaced whenever the number of repairable failures reaches N or the unrepairable failure occurs, whichever occurs first. Our purpose is to determine an optimal extended policy N∗ such that the average cost rate (i.e. the long-run average cost per unit time) of the system is minimized. The explicit expression of the average cost rate is derived, and the corresponding optimal extended policy N∗ can be determined analytically or numerically. Finally, a numerical example is given to illustrate some theoretical results of the repair model proposed in this paper.