In this paper, we study a maintenance model with general repair and two types of replacement: failure and preventive replacement. When the system fails a decision is made whether to replace or repair it. The repair degree that affects the virtual age of the system is assumed to be a random function of the repair-cost and the virtual age at failure time. The system can be preventively replaced at any time before failure. The objective is to find the repair/replacement policy minimizing the long-run expected average cost per unit time. It is shown that a generalized repair-cost-limit policy is optimal and the preventive replacement time depends on the virtual age of the system and on the length of the operating time since the last repair. Computational procedures for finding the optimal repair-cost limit and the optimal average cost are developed. This model includes many well-known models as special cases and the approach provides a unified treatment of a wide class of maintenance models.

The paper studies a model of repairable systems which is flexible enough to incorporate the standard imperfect repair and many other models from the literature. Palm stationarity of virtual ages, inter-failure times and degrees of repair is studied. A Loynes-type scheme and Harris recurrent Markov chains combined with coupling methods are used. Results on the weak total variation and moment convergences are obtained and illustrated by examples with IFR, DFR, heavy-tailed and light-tailed lifetime distributions. Some convergences obtained are monotone and/or at a geometric rate.

Stochastic comparison results for replacement policies are shown in this paper using the formalism of point processes theory. At each failure moment a repair is allowed. It is performed with a random degree of repair including (as special cases) perfect, minimal and imperfect repair models. Results for such repairable systems with schemes of planned replacements are also shown. The results are obtained by coupling methods for point processes.