Extended great deluge algorithm for the imperfect preventive maintenance optimization of multi−state systems

Abstract This paper deals with preventive maintenance optimization problem for multi-state systems (MSS). This problem was initially addressed and solved by Levitin and Lisnianski [Optimization of imperfect preventive maintenance for multi-state systems. Reliab Eng Syst Saf 2000;67:193-203]. It consists on finding an optimal sequence of maintenance actions which minimizes maintenance cost while providing the desired system reliability level. This paper proposes an approach which improves the results obtained by genetic algorithm (GENITOR) in Levitin and Lisnianski [Optimization of imperfect preventive maintenance for multi-state systems. Reliab Eng Syst Saf 2000;67:193-203]. The considered MSS have a range of performance levels and their reliability is defined to be the ability to meet a given demand. This reliability is evaluated by using the universal generating function technique. An optimization method based on the extended great deluge algorithm is proposed. This method has the advantage over other methods to be simple and requires less effort for its implementation. The developed algorithm is compared to than in Levitin and Lisnianski [Optimization of imperfect preventive maintenance for multi-state systems. Reliab Eng Syst Saf 2000;67:193-203] by using a reference example and two newly generated examples. This comparison shows that the extended great deluge gives the best solutions (i.e. those with minimal costs) for 8 instances among 10.

Selective maintenance optimisation for series-parallel systems alternating missions and scheduled breaks with stochastic durations

This paper deals with the selective maintenance problem for a multi-component system performing consecutive missions separated by scheduled breaks. To increase the probability of successfully completing its next mission, the system components are maintained during the break. A list of potential imperfect maintenance actions on each component, ranging from minimal repair to replacement is available. The general hybrid hazard rate approach is used to model the reliability improvement of the system components. Durations of the maintenance actions, the mission and the breaks are stochastic with known probability distributions. The resulting optimisation problem is modelled as a non-linear stochastic programme. Its objective is to determine a cost-optimal subset of maintenance actions to be performed on the components given the limited stochastic duration of the break and the minimum system reliability level required to complete the next mission. The fundamental concepts and relevant parameters of this decision-making problem are developed and discussed. Numerical experiments are provided to demonstrate the added value of solving this selective maintenance problem as a stochastic optimisation programme

Firm productivity, profit and business goal satisfaction: an assessment of maintenance decision effects on small and medium scale enterprises (SME’s)

[EN] This study was carried out to identify which factors are most relevant to managers of SMEs in maintenance decision making, and to investigate how these factors influence the realization of business goals satisfactorily, using structural equation modelling, partial least square design (PLS-SEM) to establish significant relationships between manifest and latent variables. A study of maintenance cost vis a vis the number of maintenance works carried out and profits realized was conducted to ascertain correlations and identify which factors played key roles in profit maximization. Results showed that with increasing level of maintenance for SMEs, profit margins reduced significantly. Also, an R2 value of 0.83 showed that the latent variable, business goal satisfaction was explained to a high degree (83%) by the manifest variables. Rentals of equipment from third parties (0.27), halting production (0.11) and outsourcing (0.39) were less considered for business sustainability per correlation coefficients than funds (0.79), and the possibilities to carry out both corrective (0.64) and preventive (0.58) maintenance works.  F-square value greater than zero was realized (0.387) and this showed reliability of the both inner and outer models. These findings can be used in building a decision tool or framework that will best suit SMEs with high financial budget constraints.Owusu-Mensah, D.; Quaye, EK.; Brako, L. (2021). Firm productivity, profit and business goal satisfaction: an assessment of maintenance decision effects on small and medium scale enterprises (SME’s). Journal of Applied Research in Technology & Engineering. 2(1):23-31. https://doi.org/10.4995/jarte.2021.14615OJS233121Al-Tabbaa, O., Ankrah, S. (2016). 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Reliab Eng Syst Safety, 137(2), 76-86. https://doi.org/10.1016/j.ress.2015.01.002Liu, X., Zheng, J., Fu, J., Ji, J., Chen, G. (2017). Multi-level optimization of maintenance plan for natural gas pipeline systems subject to external corrosion. Journal of Natural Gas Science and Engineering, 50, 64-73. https://doi.org/10.1016/j.jngse.2017.11.021Ma, J., Cheng, L., Li, D. (2018). Road Maintenance Optimization Model Based on Dynamic Programming in Urban Traffic Network. Journal of Advanced Transportation. Article ID 4539324, 11 pages. https://doi.org/10.1155/2018/4539324Marquez, A.C., Gupta, J.N.D. (2006). Contemporary maintenance management: process, framework and supporting pillars. Omega, 34(3), 313-326. https://doi.org/10.1016/j.omega.2004.11.003Nourelfath, M., Nahas, N. & Ben-Daya, M. (2015). Integrated preventive maintenance and production decisions for imperfect processes. Reliab Eng Syst Safety, 148, 21-31. https://doi.org/10.1016/j.ress.2015.11.015Olivotti D., Passlick J., Dreyer S., Lebek B., Breitner M.H. (2018) Maintenance Planning Using Condition Monitoring Data. In: Kliewer N., Ehmke J., Borndörfer R.(eds) Operations Research Proceedings 2017. https://doi.org/10.1007/978-3-319-89920-6_72Pallant, J. (2007). SPSS survival manual, 3rd. Edition. McGrath Hill.Parida, A., Kumar, U. (2016). Applications and Case Studies. Maintenance performance measurement (MPM): issues and challenges. Journal of Quality in Maintenance Engineering, 12(3), 239-251. https://doi.org/10.1108/13552510610685084Qiu, Q., Cui, L., Shen, J., Yang, L. (2017). Optimal maintenance policy considering maintenance errors for systems operating under performance-based contracts. Comput Industr Eng., 112, 147-155. https://doi.org/10.1016/j.cie.2017.08.025Ruschel, E., Santos, E.A.P. & Loures, E.D.F.R. (2017). Industrial maintenance decision-making: a systematic literature review. J Manuf Syst., 45, 180-194. https://doi.org/10.1016/j.jmsy.2017.09.003Shayesteh, E., Yu, J., Hilber, P. (2018). Maintenance optimization of power systems with renewable energy sources integrated. Energy, 149, 577-586. https://doi.org/10.1016/j.energy.2018.02.066Shen, J., Zhu, K. (2017). An uncertain single machine scheduling problem with periodic maintenance. Knowledge-Based Systems, 144, 32-41. https://doi.org/10.1016/j.knosys.2017.12.021Stebbins, R. A. (2001). Exploratory research in the social sciences (Vol. 48). Sage.Van, P.D., Bérenguer, C. (2012). Condition-based maintenance with imperfect preventive repairs for a deteriorating production system. Qual Reliab Eng., 28(6), 624-633. https://doi.org/10.1002/qre.1431Verbert, K., Schutter, B.D., Babuska, R. (2017). Timely condition-based maintenance planning for multi-component systems. Reliab Eng Syst Safety, 159, 310-321. https://doi.org/10.1016/j.ress.2016.10.032Yang, L., Ma, X., Zhao, Y. (2017). 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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

After-sales services optimisation through dynamic opportunistic maintenance: a wind energy case study

After-sales maintenance services can be a very profitable source of incomes for original equipment manufacturers (OEM) due to the increasing interest of assets’ users on performance-based contracts. However, when it concerns the product value-adding process, OEM have traditionally been more focused on improving their production processes, rather than on complementing their products by offering after-sales services; consequently leading to difficulties in offering them efficiently. Furthermore, both due to the high uncertainty of the assets’ behaviour and the inherent challenges of managing the maintenance process (e.g. maintenance strategy to be followed or resources to be deployed), it is complex to make business out of the provision of after-sales services. With the aim of helping the business and maintenance decision makers at this point, this paper proposes a framework for optimising the incomes of after-sales maintenance services through: 1) implementing advanced multi-objective opportunistic maintenance strategies that sistematically consider the assets’ operational context in order to perform preventive maintenance during most favourable conditions, 2) considering the specific OEMs’ and users’ needs, and 3) assessing both internal and external uncertainties that might condition the after-sales services’ success. The developed case study for the wind energy sector demonstrates the suitability of the presented framework for optimising the after-sales services.EU Framework Programme Horizon 2020, MSCA-RISE-2014: Marie Skłodowska-Curie Research and Innovation Staff Exchange (RISE) (grant agreement number 645733- Sustain-Owner-H2020-MSCA-RISE-2014) and the EmaitekPlus 2016-2017 Program of the Basque Government

Supporting group maintenance through prognostics-enhanced dynamic dependability prediction

Condition-based maintenance strategies adapt maintenance planning through the integration of online condition monitoring of assets. The accuracy and cost-effectiveness of these strategies can be improved by integrating prognostics predictions and grouping maintenance actions respectively. In complex industrial systems, however, effective condition-based maintenance is intricate. Such systems are comprised of repairable assets which can fail in different ways, with various effects, and typically governed by dynamics which include time-dependent and conditional events. In this context, system reliability prediction is complex and effective maintenance planning is virtually impossible prior to system deployment and hard even in the case of condition-based maintenance. Addressing these issues, this paper presents an online system maintenance method that takes into account the system dynamics. The method employs an online predictive diagnosis algorithm to distinguish between critical and non-critical assets. A prognostics-updated method for predicting the system health is then employed to yield well-informed, more accurate, condition-based suggestions for the maintenance of critical assets and for the group-based reactive repair of non-critical assets. The cost-effectiveness of the approach is discussed in a case study from the power industry

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