Return of products within the warranty coverage induces additional cost and loss of reputation to manufacturers. It is of practical interest to predict the return rate by experimental means before introducing a product to the market. In this paper, we propose to optimize accelerated reliability tests to achieve the goal within limited time. To describe the heterogeneity in the customers’ usage mode, a discrete random variable is employed to model the degradation rate in addition to the continuous stress variable. To further characterize the heterogeneity in the customers’ behavior, two models of product return are investigated: one assumes that customers return products once the degradation level reaches the minimum eligible return threshold and the other assumes that the threshold varies among different customers. Optimal reliability tests are planned under the large-sample assumption with two novel test schemes: global optimal planning and stress constrained planning. Insights regarding the optimal plans are gleaned to ameliorate the test planning procedure and verify the optimality. A real example from the battery industry is then presented along with the simulation study and sensitivity analysis to demonstrate the methods. We find that the randomness in return level results in different test plans. Furthermore, the constrained optimal plans offer more robustness to the compromise plans.

The gamma distribution is one of the most important parametric models in probability theory and statistics. Although a multitude of studies have theoretically investigated the properties of the gamma distribution in the literature, there is still a serious lack of tailored statistical tools to facilitate its practical applications. To fill the gap, this paper develops a comprehensive R package for the gamma distribution. In specific, the R package focuses on the following three important tasks: generate the gamma random variables, estimate the model parameters, and construct statistical limits, including confidence limits, prediction limits, and tolerance limits based on the gamma random variables. The proposed package encompasses the state-of-the-art methods of the gamma distribution in the literature and its usage is illustrated by a real application.

This study proposes a framework to analyze accelerated degradation testing (ADT) data in the presence of inspection effects. Motivated by a real dataset from the electric industry, we study two types of effects induced by inspections. After each inspection, the system degradation level instantaneously reduces by a random value. Meanwhile, the degrading rate is elevated afterwards. Considering the absence of observations due to practical reasons, we employ the expectation–maximization (EM) algorithm to analytically estimate the unknown parameters in a stepwise Wiener degradation process with covariates. Moreover, to maintain the level of generality for the adaption of the method in various scenarios, a confidence density approach is utilized to hierarchically estimate the parameters in the acceleration link function. The proposed methods can provide efficient parameter estimation under complex link functions with multiple stress factors. Further, confidence intervals are derived based on the large-sample approximation. Simulation studies and a case study from Schneider Electric are used to illustrate the proposed methods. The results show that the proposed model yields a remarkably better fit to the Schneider data in comparison to the conventional Wiener ADT model.