Repair Network Buffer Planning for Unserviceable Parts
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Solution Overview
Problem
Existing repair planning techniques are inadequate in minimizing costs associated with broken or unusable parts in supply chains, leading to inefficient use of resources and increased costs due to unnecessary storage, diagnosis, and shipping within repair networks.
Innovation Solution
A method for repair planning that models unserviceable parts into different buffers based on inspection outcomes, allowing for on-demand repair planning by determining the earliest time parts can be repaired or moved to satisfy demands, utilizing inspection and move lead times to optimize when repairs and movements occur, enabling 'just-in-time' repair and movement decisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If parts are inspected and repaired immediately upon receipt at repair locations, then the availability of serviceable parts is improved, but the costs associated with storage, diagnosis, and repair operations increase
Solution Approach 1:
The system performs preliminary classification of unserviceable parts into multiple buffers based on inspection outcomes before repair decisions are made. Parts are categorized into buffers such as repairable at this location, repairable at upstream locations, and non-repairable, allowing for optimized repair planning that delays actual repair operations until necessary while maintaining part availability tracking
Solution Approach 2:
The system dynamically determines repair timing and location based on real-time buffer status and demand requirements. Repair operations are scheduled to occur at the latest possible time that still satisfies serviceable part availability needs, adapting repair plans as parts move through different buffers and as demand conditions change
2Loss of energy
If parts are kept in buffer storage awaiting repair decisions, then unnecessary repair operations are avoided, but parts may sit idle and become obsolete
Solution Approach 1:
The system performs preliminary classification of unserviceable parts into multiple buffers based on inspection outcomes before repair decisions are made. Parts are categorized into buffers such as repairable at this location, repairable at upstream locations, and non-repairable, allowing for optimized repair planning that delays actual repair operations until necessary while maintaining part availability tracking
Solution Approach 2:
The system continuously monitors buffer status and provides feedback on part availability and repair timing. This feedback mechanism enables the system to determine the latest possible time for repair operations that still satisfy demand requirements, preventing both premature repair and excessive delays that would cause obsolescence
3Adaptability or versatility
If multiple repair locations are utilized in the repair network, then the capability to repair diverse part types is improved, but the complexity of coordinating part movement and repair timing increases
Solution Approach 1:
The system segments the repair network into multiple hierarchical levels with different repair capabilities. Repair locations are organized such that downstream locations handle simpler repairs while upstream locations handle more complex repairs. This segmentation allows diverse part types to be routed to appropriate repair locations based on their specific repair needs, reducing coordination complexity through structured hierarchy
Solution Approach 2:
The system adds a temporal dimension to the repair coordination process by determining the latest possible time for each repair operation. This time-based planning approach transforms the complex multi-location coordination problem into a more manageable scheduling problem, where repair timing and location decisions are integrated through the lens of when serviceable parts are needed
Data Source
AI summary
In one embodiment, a method for repair planning for a location in a repair network includes modeling: (1) an uninspected buffer for parts received but not yet inspected at the location; (2) a first buffer for parts inspected at the location and repairable at the location; (3) a second buffer for parts inspected at the location and not repairable at the location; (4) a third buffer for parts inspected at the location and not repairable at any location in the repair network; and (5) a fourth buffer for parts inspected at the location and serviceable without repair. The parts in the uninspected buffer are assigned to the first, second, third, and fourth buffers at corresponding rates according to an inspection operation. One or more operation plans are generated to push parts out of the uninspected buffer to the first, second, third, and fourth buffers according to the corresponding rates, a part pushed out being available within the first, second, third, or fourth buffer only after a predetermined disposition time has elapsed. An operation plan is generated to push parts out of the second buffer to one or more upstream locations, a part pushed out being available at an upstream location only after a predetermined move lead time has elapsed. For each part pushed out of the uninspected buffer to the first or second buffer, the earliest time at which repair can begin for the part is estimated, this earliest repair time determining the earliest time at which, after the part has been repaired to make it serviceable, the part can be available to satisfy a demand at the location.