Opportunistic Preventive Maintenance Scheduling Based on Theory of Constraints

Abstract In recent years, to improve system reliability and economy, machine maintenance strategies have been paid more and more intention by researchers. This paper aims to integrate the concept of theory of constraints (TOC) into multi-machine opportunistic maintenance policy. Based on the preventive maintenance algorithm, an improved model containing bottleneck strategy which influences opportunistic maintenance has been developed. By maximizing total cost saving, an optimal maintenance schedule of all machines in a series product line can be obtained. The results of a case study show that this model is valid for planning a comprehensive optimal maintenance schedule. Furthermore, by comparing with other models, this model has been proven to be more effectively especially in series product lines with bottleneck

Integration of production, maintenance and quality : Modelling and solution approaches

Dans cette thèse, nous analysons le problème de l'intégration de la planification de production et de la maintenance préventive, ainsi que l'élaboration du système de contrôle de la qualité. Premièrement, on considère un système de production composé d'une machine et de plusieurs produits dans un contexte incertain, dont les prix et le coût changent d'une période à l'autre. La machine se détériore avec le temps et sa probabilité de défaillance, ainsi que le risque de passage à un état hors contrôle augmentent. Le taux de défaillance dans un état dégradé est plus élevé et donc, des coûts liés à la qualité s’imposent. Lorsque la machine tombe en panne, une maintenance corrective ou une réparation minimale seront initiées pour la remettre en marche sans influer ses conditions ou le processus de détérioration. L'augmentation du nombre de défaillances de la machine se traduit par un temps d'arrêt supérieur et un taux de disponibilité inférieur. D'autre part, la réalisation des plans de production est fortement influencée par la disponibilité et la fiabilité de la machine. Les interactions entre la planification de la maintenance et celle de la production sont incorporées dans notre modèle mathématique. Dans la première étape, l'effet de maintenance sur la qualité est pris en compte. La maintenance préventive est considérée comme imparfaite. La condition de la machine est définie par l’âge actuel, et la machine dispose de plusieurs niveaux de maintenance avec des caractéristiques différentes (coûts, délais d'exécution et impacts sur les conditions du système). La détermination des niveaux de maintenance préventive optimaux conduit à un problème d’optimisation difficile. Un modèle de maximisation du profit est développé, dans lequel la vente des produits conformes et non conformes, les coûts de la production, les stocks tenus, la rupture de stock, la configuration de la machine, la maintenance préventive et corrective, le remplacement de la machine et le coût de la qualité sont considérés dans la fonction de l’objectif. De plus, un système composé de plusieurs machines est étudié. Dans cette extension, les nombres optimaux d’inspections est également considéré. La fonction de l’objectif consiste à minimiser le coût total qui est la somme des coûts liés à la maintenance, la production et la qualité. Ensuite, en tenant compte de la complexité des modèles préposés, nous développons des méthodes de résolution efficaces qui sont fondées sur la combinaison d'algorithmes génétiques avec des méthodes de recherches locales. On présente un algorithme mimétique qui emploi l’algorithme Nelder-Mead, avec un logiciel d'optimisation pour déterminer les valeurs exactes de plusieurs variables de décisions à chaque évaluation. La méthode de résolution proposée est comparée, en termes de temps d’exécution et de qualités des solutions, avec plusieurs méthodes Métaheuristiques. Mots-clés : Planification de la production, Maintenance préventive imparfaite, Inspection, Qualité, Modèles intégrés, MétaheuristiquesIn this thesis, we study the integrated planning of production, maintenance, and quality in multi-product, multi-period imperfect systems. First, we consider a production system composed of one machine and several products in a time-varying context. The machine deteriorates with time and so, the probability of machine failure, or the risk of a shift to an out-of-control state, increases. The defective rate in the shifted state is higher and so, quality related costs will be imposed. When the machine fails, a corrective maintenance or a minimal repair will be initiated to bring the machine in operation without influencing on its conditions or on the deterioration process. Increasing the expected number of machine failures results in a higher downtime and a lower availability rate. On the other hand, realization of the production plans is significantly influenced by the machine availability and reliability. The interactions between maintenance scheduling and production planning are incorporated in the mathematical model. In the first step, the impact of maintenance on the expected quality level is addressed. The maintenance is also imperfect and the machine conditions after maintenance can be anywhere between as-good-as-new and as-bad-as-old situations. Machine conditions are stated by its effective age, and the machine has several maintenance levels with different costs, execution times, and impacts on the system conditions. High level maintenances on the one hand have greater influences on the improvement of the system state and on the other hand, they occupy more the available production time. The optimal determination of such preventive maintenance levels to be performed at each maintenance intrusion is a challenging problem. A profit maximization model is developed, where the sale of conforming and non-conforming products, costs of production, inventory holding, backorder, setup, preventive and corrective maintenance, machine replacement, and the quality cost are addressed in the objective function. Then, a system with multiple machines is taken into account. In this extension, the number of quality inspections is involved in the joint model. The objective function minimizes the total cost which is the sum of maintenance, production and quality costs. In order to reduce the gap between the theory and the application of joint models, and taking into account the complexity of the integrated problems, we have developed an efficient solution method that is based on the combination of genetic algorithms with local search and problem specific methods. The proposed memetic algorithm employs Nelder-Mead algorithm along with an optimization package for exact determination of the values of several decision variables in each chromosome evolution. The method extracts not only the positive knowledge in good solutions, but also the negative knowledge in poor individuals to determine the algorithm transitions. The method is compared in terms of the solution time and quality to several heuristic methods. Keywords : Multi-period production planning, Imperfect preventive maintenance, Inspection, Quality, Integrated model, Metaheuristic

Power system reliability enhancement with reactive power compensation and operational risk assessment with smart maintenance for power generators

Modern power systems incorporate advanced contingency measures with the aim of enhancing system performance. Among them, the strategical installation of reactive power compensators into a power system is commonly practised to minimize power losses and improve system reliability. Such a practice requires a robust optimization technique that could reduce the computational burden and provide optimal planning and operation of the compensators. This thesis proposes an advanced optimization technique, named as Accelerated Quantum Particle Swarm Optimization (AQPSO) to determine the optimal placement, sizing and dispatch strategy of the reactive power compensators with the aim of improving the system level reliability. The uniqueness of the technique is the incorporation of the concept ‘best observation’, which accelerates the search towards the optimal solution. The implementation of advanced maintenance strategies is another common contingency measure used to enhance system performance. In this context, this thesis proposes a novel Smart Maintenance (SM) strategy for power generators that maximize the generation adequacy and provide increased economic benefits in a framework of system reliability. The uniqueness of the SM approach is the incorporation of the ‘obsolescence’ state through the stages of the bathtub curve and half-arch shape to model the aging process and then quantify the operational risk of the generators using fuzzy logic theory. Further, SM combines the proposed AQPSO and Sequential Median Latin Hypercube to obtain a comprehensive maintenance schedule. The investigation presented in this thesis contributes with novel AQPSO-based algorithms to enhance power system reliability with the operation of reactive power compensation; a more realistic and accurate aging reliability model of power generators; a detailed SM mathematical framework and an algorithm for the scheduling of proactive maintenance of generators of small and large-power systems. The proposed models are significant in the journey to the smart operation of a power system with diverse levels of applications

Generator maintenance scheduling

Διπλωματική εργασία--Πανεπιστήμιο Μακεδονίας, Θεσσαλονίκη, 2019.The ongoing Electricity markets restructuring on a global scale, shifted much attention from centralized and in particular small isolated systems, typically found in islands. It is true that such systems, mainly run on liquid fuel Gensets, if not interconnected to some major grid may ever exhibit investment interest. As a result, many utilities constantly struggle while others due to fuel cost and the ever-increasing emission control restrictions, are near the verge to collapse. It is this necessity that actually urges for optimal managerial practices to exploit the last penny spent until-if ever, all these resource guzzling Gensets reach their retirement age. In this thesis we respect a realistic power plant feeding the tourist industry of an island. A 0/1 MILP formulation enables to accurately account for operation, maintenance and reliability status cost, providing in practical time a palette full of decision options. System demand is allocated in classes whereas the overall proposed reliability approach renders any chosen optimal schedule easily implemented in practice

Optimal Ship Maintenance Scheduling Under Restricted Conditions and Constrained Resources

The research presented in this dissertation addresses the application of evolution algorithms, i.e. Genetic Algorithm (GA) and Differential Evolution algorithm (DE) to scheduling problems in the presence of restricted conditions and resource limitations. This research is motivated by the scheduling of engineering design tasks in shop scheduling problems and ship maintenance scheduling problems to minimize total completion time. The thesis consists of two major parts; the first corresponds to the first appended paper and deals with the computational complexity of mixed shop scheduling problems. A modified Genetic algorithm is proposed to solve the problem. Computational experiments, conducted to evaluate its performance against known optimal solutions for different sized problems, show its superiority in computation time and the high applicability in practical mixed shop scheduling problems. The second part considers the major theme in the second appended paper and is related to the ship maintenance scheduling problem and the extended research on the multi-mode resource-constrained ship scheduling problem. A heuristic Differential Evolution is developed and applied to solve these problems. A mathematical optimization model is also formulated for the multi-mode resource-constrained ship scheduling problem. Through the computed results, DE proves its effectiveness and efficiency in addressing both single and multi-objective ship maintenance scheduling problem

Preventive maintenance and replacement scheduling : models and algorithms.

Preventive maintenance is a broad term that encompasses a set of activities aimed at improving the overall reliability and availability of a system. Preventive maintenance involves a basic trade-off between the costs of conducting maintenance/replacement activities and the cost savings achieved by reducing the overall rate of occurrence of system failures. Designers of preventive maintenance schedules must weigh these individual costs in an attempt to minimize the overall cost of system operation. They may also be interested in maximizing the system reliability, subject to some sort of budget constraint. In this dissertation, we present a complete discussion about the problem definition and review the literature. We develop new nonlinear mixed-integer optimization models, solve them by standard nonlinear optimization algorithms, and analyze their computational results. In addition, we extend the optimization models by considering engineering economy features and reformulate them as a multi-objective optimization model. We optimize this model by generational and steady state genetic algorithms as well as by a simulated annealing algorithm and demonstrate the computational results obtained by implementation of these algorithms. We perform a sensitivity analysis on the parameters of the optimization models and present a comparison between exact and metaheuristic algorithms in terms of computational efficiency and accuracy. Finally, we present a new mathematical function to model age reduction and improvement factor parameter used in optimization models. In addition, we develop a practical procedure to estimate the effect of maintenance activity on failure rate and effective age of multi component systems