Sensitivity analysis of machine repair problems in manufacturing systems with service interruptions

This paper models a manufacturing system consisting of M operating machines and S spare machines under the supervision of a group of technicians in a repair facility. Machines fail according to a Poisson process, and the repair (service) process of a failed machine may require more than one phase. In each phase, service times are assumed to be exponentially distributed but may be interrupted when the repair facility encounters unpredictable breakdowns. Two models of manufacturing systems are considered. In the first model, technicians repair failed machines at different rates in each phase. In the second model, a two-phase service system with differing numbers of technicians is considered. Profit functions are developed for both models and optimized by a suitable allocation of the number of machines, spares, and technicians in the system. Finally, a sensitivity analysis (see Cao [X.R. Cao, Realization Probabilities: The Dynamics of Queuing Systems, Springer-Verlag: London, 1994; X.R. Cao, The relations among potentials, perturbation analysis, and Markov decision processes, Discrete Event Dynam. Syst.: Theory Applicat. 8 (1998) 71–87]) is performed to provide an approach that quantifies the impact of changes in the parameters on the profit models.