Techniques for Optimum Spares Allocation: A Tutorial Review

In many modern complex systems the problem of achieving high reliability leads to the use of interchangeable modular components accompanied by a stock of spare parts. This paper examines, compares, and assesses several of the techniques presented in the literature for allocating the numbers of spares of each part type to be stocked in order to maximize the system reliability subject to constraints on resources (i.e., weight, volume, cost, etc.). The problem of optimum spares allocation is complicated since resources are consumed in a discrete fashion and the expression for the system reliability is a nonlinear transcendental function. The classical dynamic programming algorithm produces all optimal spares allocations; however, the solution can become computationally intractable even with the aid of a modern high-speed digital computer. In the case of multiple constraints the time problem is vastly exacerbated. In such a case one must turn to a procedure that yields a near-optimal solution in a reasonable amount of computer time. Two approximate methods discussed in this paper are the incremental reliability per pound algorithm and the Lagrange multiplier algorithm. These algorithms are readily adaptable to handle multiple constraints. Computer programs are developed for each of the three optimization algorithms and are utilized to obtain the spares allocation for a few systems. The optimization theory presented is directly applicable to series or parallel systems. A concluding example illustrates how this can be extended to certain series-parallel systems.