Optimal maintenance of multi-component systems: a review

In this article we give an overview of the literature on multi-component maintenance optimization. We focus on work appearing since the 1991 survey "A survey of maintenance models for multi-unit systems" by Cho and Parlar. This paper builds forth on the review article by Dekker et al. (1996), which focusses on economic dependence, and the survey of maintenance policies by Wang (2002), in which some group maintenance and some opportunistic maintenance policies are considered. Our classification scheme is primarily based on the dependence between components (stochastic, structural or economic). Next, we also classify the papers on the basis of the planning aspect (short-term vs long-term), the grouping of maintenance activities (either grouping preventive or corrective maintenance, or opportunistic grouping) and the optimization approach used (heuristic, policy classes or exact algorithms). Finally, we pay attention to the applications of the models.literature review;economic dependence;failure interaction;maintenance policies;grouping maintenance;multi-component systems;opportunistic maintenance;maintencance optimization;structural dependence

Preventive replacement for belligerent systems

A mortar is commonly used as an indirect firing weapon to support close fires with a variety of ammunition. There are mortar weapons with various shells. Each type of shells fired by mortars does damage to a weapon when the total damage on a mortar weapon reaches the tolerance limit, the mortar weapon either fails or explodes, leading to a compulsory replacement which is costly. In order to maintain the mortar weapons and archers in wars, a research was conducted to find the best number of mortar shells that will be fired until a preventive replacement for mortar weapons is implemented

Estimation of component redundancy in optimal age maintenance

The classical Optimal Age-Replacement defines the maintenance strategy based on the equipment failure consequences. For severe consequences an early equipment replacement is recommended. For minor consequences the repair after failure is proposed. One way of reducing the failure consequences is the use of redundancies, especially if the equipment failure rate is decreasing over time, since in this case the preventive replacement does not reduce the risk of failure. The estimation of an active component redundancy degree is very important in order to minimize the life-cycle cost. If it is possible to make these estimations in the early phase of system design, the implementation is easier and the amortization faster. This work proposes an adaptation of the Optimal Age-Replacement method in order to simultaneously optimize the equipment redundancy allocation and the maintenance plan. The main goal is to provide a simple methodology, requiring the fewer data possible. A set of examples are presented illustrating that this methodology covers a wide variety of operating conditions. The optimization of the number of repairs between each replacement, in the cases of imperfect repairs, is another feature of this methodology

A unified methodology of maintenance management for repairable systems based on optimal stopping theory

This dissertation focuses on the study of maintenance management for repairable systems based on optimal stopping theory. From reliability engineering’s point of view, all systems are subject to deterioration with age and usage. System deterioration can take various forms, including wear, fatigue, fracture, cracking, breaking, corrosion, erosion and instability, any of which may ultimately cause the system to fail to perform its required function. Consequently, controlling system deterioration through maintenance and thus controlling the risk of system failure becomes beneficial or even necessary. Decision makers constantly face two fundamental problems with respect to system maintenance. One is whether or when preventive maintenance should be performed in order to avoid costly failures. The other problem is how to make the choice among different maintenance actions in response to a system failure. The whole purpose of maintenance management is to keep the system in good working condition at a reasonably low cost, thus the tradeoff between cost and condition plays a central role in the study of maintenance management, which demands rigorous optimization. The agenda of this research is to develop a unified methodology for modeling and optimization of maintenance systems. A general modeling framework with six classifying criteria is to be developed to formulate and analyze a wide range of maintenance systems which include many existing models in the literature. A unified optimization procedure is developed based on optimal stopping, semi-martingale, and lambda-maximization techniques to solve these models contained in the framework. A comprehensive model is proposed and solved in this general framework using the developed procedure which incorporates many other models as special cases. Policy comparison and policy optimality are studied to offer further insights. Along the theoretical development, numerical examples are provided to illustrate the applicability of the methodology. The main contribution of this research is that the unified modeling framework and systematic optimization procedure structurize the pool of models and policies, weed out non-optimal policies, and establish a theoretical foundation for further development

Optimal Burn-in Time and Imperfect Maintenance Strategy for a Warranted Product with Bathtub Shaped Failure Rate

‘Burn-in/preventive maintenance’ programme is an efficient approach used to minimise the warranty servicing cost of a product with bathtub shaped failure rate. Burn-in is a widely used method to improve the quality of product during its ‘infant mortality’ period and preventive maintenance is a scheduled necessary activity carried out during its ‘wear-out’ period. In this paper, an optimisation model is developed to determine the optimal burn-in time and optimal imperfect preventive maintenance strategy that minimises the total mean servicing cost of a warranted product with an age-dependent repair cost. We provide a numerical study to illustrate our results

Reliability and Condition-Based Maintenance Analysis of Deteriorating Systems Subject to Generalized Mixed Shock Model

For successful commercialization of evolving devices (e.g., micro-electro-mechanical systems, and biomedical devices), there must be new research focusing on reliability models and analysis tools that can assist manufacturing and maintenance of these devices. These advanced systems may experience multiple failure processes that compete against each other. Two major failure processes are identified to be deteriorating or degradation processes (e.g., wear, fatigue, erosion, corrosion) and random shocks. When these failure processes are dependent, it is a challenging problem to predict reliability of complex systems. This research aims to develop reliability models by exploring new aspects of dependency between competing risks of degradation-based and shock-based failure considering a generalized mixed shock model, and to develop new and effective condition-based maintenance policies based on the developed reliability models. In this research, different aspects of dependency are explored to accurately estimate the reliability of complex systems. When the degradation rate is accelerated as a result of withstanding a particular shock pattern, we develop reliability models with a changing degradation rate for four different shock patterns. When the hard failure threshold reduces due to changes in degradation, we investigate reliability models considering the dependence of the hard failure threshold on the degradation level for two different scenarios. More generally, when the degradation rate and the hard failure threshold can simultaneously transition multiple times, we propose a rich reliability model for a new generalized mixed shock model that is a combination of extreme shock model, δ-shock model and run shock model. This general assumption reflects complex behaviors associated with modern systems and structures that experience multiple sources of external shocks. Based on the developed reliability models, we introduce new condition-based maintenance strategies by including various maintenance actions (e.g., corrective replacement, preventive replacement, and imperfect repair) to minimize the expected long-run average maintenance cost rate. The decisions for maintenance actions are made based on the health condition of systems that can be observed through periodic inspection. The reliability and maintenance models developed in this research can provide timely and effective tools for decision-makers in manufacturing to economically optimize operational decisions for improving reliability, quality and productivity.Industrial Engineering, Department o

Optimal Periodic Inspection of a Stochastically Degrading System

This thesis develops and analyzes a procedure to determine the optimal inspection interval that maximizes the limiting average availability of a stochastically degrading component operating in a randomly evolving environment. The component is inspected periodically, and if the total observed cumulative degradation exceeds a fixed threshold value, the component is instantly replaced with a new, statistically identical component. Degradation is due to a combination of continuous wear caused by the component\u27s random operating environment, as well as damage due to randomly occurring shocks of random magnitude. In order to compute an optimal inspection interval and corresponding limiting average availability, a nonlinear program is formulated and solved using a direct search algorithm in conjunction with numerical Laplace transform inversion. Techniques are developed to significantly decrease the time required to compute the approximate optimal solutions. The mathematical programming formulation and solution techniques are illustrated through a series of increasingly complex example problems

Optimal maintenance of multi-component systems: a review

In this article we give an overview of the literature on multi-component maintenance optimization. We focus on work appearing since the 1991 survey "A survey of maintenance models for multi-unit systems" by Cho and Parlar. This paper builds forth on the review article by Dekker et al. (1996), which focusses on economic dependence, and the survey of maintenance policies by Wang (2002), in which some group maintenance and some opportunistic maintenance policies are considered. Our classification scheme is primarily based on the dependence between components (stochastic, structural or economic). Next, we also classify the papers on the basis of the planning aspect (short-term vs long-term), the grouping of maintenance activities (either grouping preventive or corrective maintenance, or opportunistic grouping) and the optimization approach used (heuristic, policy classes or exact algorithms). Finally, we pay attention to the applications of the models

A geometric-process maintenance model for a deteriorating system under a random environment

This paper studies a geometric-process maintenance-model for a deteriorating system under a random environment. Assume that the number of random shocks, up to time t, produced by the random environment forms a counting process. Whenever a random shock arrives, the system operating time is reduced. The successive reductions in the system operating time are statistically independent and identically distributed random variables. Assume that the consecutive repair times of the system after failures, form an increasing geometric process; under the condition that the system suffers no random shock, the successive operating times of the system after repairs constitute a decreasing geometric process. A replacement policy N, by which the system is replaced at the time of the failure N, is adopted. An explicit expression for the average cost rate (long-run average cost per unit time) is derived. Then, an optimal replacement policy is determined analytically. As a particular case, a compound Poisson process model is also studied.published_or_final_versio

Maintenance Strategies Design and Assessment Using a Periodic Complexity Approach

People become more dependent on various devices, which do deteriorate over time and their operation becomes more complex. This leads to higher unexpected failure chance, which causes inconvenience, cost, time, and even lives. Therefore, an efficient maintenance strategy that reduces complexity should be established to ensure the system performs economically as designed without interruption. In the current research, a comprehensive novel approach is developed for designing and evaluating maintenance strategies that effectively reduce complexity in a cost efficient way with maximum availability and quality. A proper maintenance strategy application needs a rigorous failure definition. A new complexity based mathematical definition of failure is introduced that is able to model all failure types. A complexity-based metric, complication rate , is introduced to measure functionality degradation and gradual failure. Maintenance reduces the system complexity by system resetting via introducing periodicity. A metric for measuring the amount of periodicity introduced by maintenance strategy is developed. Developing efficient maintenance strategies that improve system performance criteria, requires developing the mathematical relationships between maintenance and quality, availability, and cost. The first relation relating the product quality to maintenance policy is developed using the virtual age concept. The aging intensity function is then deployed to develop the relation between maintenance and availability. The relation between maintenance and cost is formulated by investigating the maintenance effect on each cost element. The final step in maintenance policy design is finding the optimum periodicity level. Two approaches are investigated; weighted sum integrated with AHP and a comfort zones approach. Comfort zones is a new developed physical programming based optimization heuristic that captures designer preferences and limitations without substantial efforts in tweaking or calculating weights. A mining truck case study is presented to explain the application of the developed maintenance design approach and compare its results to the traditional reward renewal theory. It is shown that the developed approach is more capable of designing a maintenance policy that reduces complexity and simultaneously improves some other performance measures. This research explains that considering complexity reduction in maintenance policy design improves system functionality, and it can be achieved by simple industrially applicable approach