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

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.     

Allocation of test times in multi-state systems for reliability growth testing

This paper generalizes a reliability growth test allocation problem to series-parallel multi-state systems. An algorithm, which determines the testing time for each system element in order to maximize the entire system reliability when total testing resources are limited, is suggested. The algorithm can handle both repairable and non-repairable multi-state systems. The Crow/AMSAA reliability growth model is used to evaluate the influence of testing time on the reliability of the elements composing the system. System reliability is defined as the ability of the system to satisfy variable demand represented by a cumulative demand curve. To evaluate multi-state system reliability, a universal generating function technique is applied. A Genetic Algorithm (GA) is used as an optimization technique. The basic GA procedures adapted to the given problem are presented. Examples of the determination of reliability growth test plans are demonstrated.     

Structure optimization of multi-state system with two failure modes

When systems with two failure modes (STFM) are considered, introducing redundant elements may either increase or decrease system reliability. Therefore the problem of system structure optimization arises. In this paper we consider systems consisting of elements characterized by different reliability and nominal performance rates. Such systems are multi-state because they can have different levels of output performance depending on the combination of elements available at the moment. The algorithm that determines the structure of multi-state STFM, which maximizes system reliability and/or expected performance is presented. In this algorithm, system elements are chosen from a list of available equipment. Reliability is defined as the probability of satisfaction of given constraints imposed on system performance in both modes.The procedure developed to solve this problem is based on the use of a universal moment generating function (UMGF) for the fast evaluation of multi-state system reliability and a genetic algorithm for optimization. Basic UMGF technique operators are developed for two different types of systems, based, respectively, on transmitting capacity and on processing time. Examples of the optimization of series–parallel structures of both types are presented.     

Short communication optimal replacement scheduling in multi‐state series–parallel systems

The paper generalizes a replacement schedule optimization problem to multi‐state systems, where the system and its components have a range of performance levels—from perfect functioning to complete failure. The multi‐state system reliability is defined as the ability to satisfy a demand which is represented as a required system performance level. The reliability of system elements is characterized by their lifetime distributions with hazard rates increasing in time and is specified as expected number of failures during different time intervals. The optimal number of element replacements during the study period is defined as that which provides the desired level of the system reliability by minimum sum of maintenance cost and cost of unsupplied demand caused by failures. To evaluate multi‐state system reliability, a universal generating function technique is applied. A genetic algorithm (GA) is used as an optimization technique. Examples of the optimal replacement schedule determination are demonstrated. Copyright © 2000 John Wiley & Sons, Ltd.     

Optimal reserve management for restructured power generating systems

This paper presents a technique to determine the optimal reserve structure (reserve providers and the corresponding reserve capacity) for a restructured power generating system (GS). The reserve of a GS can be provided by its own generating units and can also be purchased from other GSs through the reserve agreements. The objective of reserve management for a GS is to minimize its total reserve cost while satisfying the reliability requirement. The reserve management is a complex optimization problem, which requires a large amount of calculations. In order to simplify the evaluation, a complex generating system (CGS) consisting of different GSs and the corresponding transmitting network is represented by its multi-state reliability equivalents. The universal generating functions (UGFs) of these equivalents are developed and the special operators for these UGFs are defined to evaluate the reliability of a particular GS, which has reserve agreements with other GSs in the CGS. The genetic algorithm (GA) has been used to solve the optimization problem. An improved power system-IEEE reliability test system is used to illustrate the technique.     

Optimizing survivability of vulnerable series–parallel multi-state systems

In this paper we consider vulnerable systems which can have different states corresponding to different combinations of available elements composing the system. Each state can be characterized by a system performance rate, which is the quantitative measure of a system's ability to perform its task. Both the impact of external factors (attack) and internal causes (failures) affect system survivability which is determined as probability of meeting a given demand.We formulate the problem of finding structure of series–parallel multi-state system (including choice of system elements, their separation and protection) in order to achieve a desired level of system survivability by the minimal cost.An algorithm based on the universal generating function method is suggested for determination of the vulnerable series–parallel multi-state system survivability. A genetic algorithm is used as optimization tool in order to solve the structure optimization problem.     

A variable neighbourhood search for integrated production and preventive maintenance planning in multi-state systems

This paper presents a variable neighbourhood search (VNS) to the integrated production and maintenance planning problem in multi-state systems. VNS is one of the most recent meta-heuristics used for problem solving in which a systematic change of neighbourhood within a local search is carried out. In the studied problem, production and maintenance decisions are co-ordinated, so that the total expected cost is minimised. We are given a set of products that must be produced in lots on a multi-state production system during a specified finite planning horizon. Planned preventive maintenance and unplanned corrective maintenance can be performed on each component of the multi-state system. The maintenance policy suggests cyclical preventive replacements of components, and a minimal repair on failed components. The objective is to determine an integrated lot-sizing and preventive maintenance strategy of the system that will minimise the sum of preventive and corrective maintenance costs, setup costs, holding costs, backorder costs and production costs, while satisfying the demand for all products over the entire horizon. We model the production system as a multi-state system with binary-state components. The formulated problem can be solved by comparing the results of several multi-product capacitated lot-sizing problems. The proposed VNS deals with the preventive maintenance selection task. Results on test instances show that the VNS method provides a competitive solution quality at economically computational expense in comparison with genetic algorithms.     

New method to minimize the preventive maintenance cost of series–parallel systems

General preventive maintenance model for input components of a system, which improves the reliability to ‘as good as new,’ was used to optimize the maintenance cost. The cost function of a maintenance policy was minimized under given availability constraint. An algorithm for first inspection vector of times was described and used on selected system example. A special ratio-criterion, based on the time dependent Birnbaum importance factor, was used to generate the ordered sequence of first inspection times. Basic system availability calculations of the paper were done by using simulation approach with parallel simulation algorithm for availability analysis. These calculations, based on direct Monte Carlo technique, were applied within the programming tool Matlab. A genetic algorithm optimization technique was used and briefly described to create the Matlab's algorithm to solve the problem of finding the best maintenance policy with a given restriction. Adjacent problem, which we called ‘reliability assurance,’ was also theoretically solved, concerning the increase of the cost when asymptotic availability value conforms to a given availability constraint.     

Optimal design of multi-state weighted k-out-of-n systems based on component design

This paper presents a study on design optimization of multi-state weighted k-out-of-n systems. The studied system reliability model is more general than the traditional k-out-of-n system model. The system and its components are capable of assuming a whole range of performance levels, varying from perfect functioning to complete failure. A utility value corresponding to each state is used to indicate the corresponding performance level. A widely studied reliability optimization problem is the “component selection problem”, which involves selection of components with known reliability and cost characteristics. Less adequately addressed has been the problem of determining system cost and utility based on the relationships between component reliability, cost and utility. This paper addresses this topic. All the optimization problems dealt with in this paper can be categorized as either minimizing the expected total system cost subject to system reliability requirements, or maximizing system reliability subject to total system cost limitation. The resulting optimization problems are too complicated to be solved by traditional optimization approaches; therefore, genetic algorithm (GA) is used to solve them. Our results show that GA is a powerful tool for solving these kinds of problems.     

A new approach to solving problems of multi‐state system reliability optimization

Usually engineers try to achieve the required reliability level with minimal cost. The problem of total investment cost minimization, subject to reliability constraints, is well known as the reliability optimization problem. When applied to multi‐state systems (MSS), the system has many performance levels, and reliability is considered as a measure of the ability of the system to meet the demand (required performance). In this case, the outage effect will be essentially different for units with different performance rate. Therefore, the performance of system components, as well as the demand, should be taken into account. In this paper, we present a technique for solving a family of MSS reliability optimization problems, such as structure optimization, optimal expansion, maintenance optimization and optimal multistage modernization. This technique combines a universal generating function (UGF) method used for fast reliability estimation of MSS and a genetic algorithm (GA) used as an optimization engine. The UGF method provides the ability to estimate relatively quickly different MSS reliability indices for series‐parallel and bridge structures. It can be applied to MSS with different physical nature of system performance measure. The GA is a robust, universal optimization tool that uses only estimates of solution quality to determine the direction of search. Copyright © 2001 John Wiley & Sons, Ltd.     

Structure optimization of multi-state system with time redundancy

In this article, a multi-state system with time redundancy where each system element has its own operation time is considered. In addition, the system total task must be performed during the restricted time. The reliability optimization problem is treated as finding the minimal cost system structure subject to the reliability constraint. A method for reliability optimization for systems with time redundancy is proposed. This method is based on the universal generating function technique for the reliability index computation and on genetic algorithm for the optimization. It provides a solution for the optimization problem for the complex series–parallel system and for the system with bridge topology. Two types of systems will illustrate the approach: systems with ordinary hot reserve and systems with work sharing between elements connected in parallel. Numerical examples are also given.     

Determination of Pareto frontier in multi-objective maintenance optimization

The objective of a maintenance policy generally is the global maintenance cost minimization that involves not only the direct costs for both the maintenance actions and the spare parts, but also those ones due to the system stop for preventive maintenance and the downtime for failure. For some operating systems, the failure event can be dangerous so that they are asked to operate assuring a very high reliability level between two consecutive fixed stops. The present paper attempts to individuate the set of elements on which performing maintenance actions so that the system can assure the required reliability level until the next fixed stop for maintenance, minimizing both the global maintenance cost and the total maintenance time. In order to solve the previous constrained multi-objective optimization problem, an effective approach is proposed to obtain the best solutions (that is the Pareto optimal frontier) among which the decision maker will choose the more suitable one. As well known, describing the whole Pareto optimal frontier generally is a troublesome task. The paper proposes an algorithm able to rapidly overcome this problem and its effectiveness is shown by an application to a case study regarding a complex series-parallel system.     

A new multi-objective optimization model for preventive maintenance and replacement scheduling of multi-component systems

In this article, a new multi-objective optimization model is developed to determine the optimal preventive maintenance and replacement schedules in a repairable and maintainable multi-component system. In this model, the planning horizon is divided into discrete and equally-sized periods in which three possible actions must be planned for each component, namely maintenance, replacement, or do nothing. The objective is to determine a plan of actions for each component in the system while minimizing the total cost and maximizing overall system reliability simultaneously over the planning horizon. Because of the complexity, combinatorial and highly nonlinear structure of the mathematical model, two metaheuristic solution methods, generational genetic algorithm, and a simulated annealing are applied to tackle the problem. The Pareto optimal solutions that provide good tradeoffs between the total cost and the overall reliability of the system can be obtained by the solution approach. Such a modeling approach should be useful for maintenance planners and engineers tasked with the problem of developing recommended maintenance plans for complex systems of components.     

Joint redundancy and maintenance optimization for multistate series–parallel systems

This paper formulates the joint redundancy and replacement schedule optimization problem generalized to multistate system, where the system and its components have a range of performance levels. Multistate system reliability is defined as the ability to maintain a specified performance level. The system elements are chosen from a list of available products on the market and the number of such elements is determined for each system component. Each element is characterized by its capacity, reliability and cost. The reliability of a system element is characterized by its lifetime distribution with the hazard rate, which increases with time. It is specified as the expected number of failures during different time intervals. The optimal system structure and the number of element replacements during the study period are defined as those which provide the desired level of system reliability with minimal sum of costs of capital investments, maintenance and unsupplied demand caused by failures. A universal generating function technique is applied to evaluate the multistate system reliability. A genetic algorithm is used as an optimization technique. Examples of determination of the optimal system structure and replacement schedule are provided.     

A combined approach to solve the redundancy optimization problem for multi-state systems under repair policies

This paper combines universal moment generating function technique with stochastic Petri nets to solve the redundancy optimization problem for multi-state systems under repair policies. Redundant elements are included in order to achieve a desirable level of production availability. The elements of the system are characterized by their cost, performance and availability. These elements are chosen from a list of products available on the market. The number of repair teams is less than the number of reparable elements, and a repair policy specifies the maintenance priorities between the system elements. A heuristic is proposed to determine the minimal cost system configuration under availability constraints. This heuristic, first applies universal moment generating function technique to evaluate the system availability, assuming unlimited maintenance resources. Once a preliminary solution is found by the optimization algorithm, stochastic Petri nets are used to model different repair policies, and to find the best system configuration (architecture and number of repairmen) in terms of global performance (availability and cost). This combined procedure is applied to a reference example.     

Joint optimization of maintenance,buffers and machines in manufacturing lines

This article considers a series manufacturing line composed of several machines separated by intermediate buffers of finite capacity. The goal is to find the optimal number of preventive maintenance actions performed on each machine, the optimal selection of machines and the optimal buffer allocation plan that minimize the total system cost, while providing the desired system throughput level. The mean times between failures of all machines are assumed to increase when applying periodic preventive maintenance. To estimate the production line throughput, a decomposition method is used. The decision variables in the formulated optimal design problem are buffer levels, types of machines and times between preventive maintenance actions. Three heuristic approaches are developed to solve the formulated combinatorial optimization problem. The first heuristic consists of a genetic algorithm, the second is based on the nonlinear threshold accepting metaheuristic and the third is an ant colony system. The proposed heuristics are compared and their efficiency is shown through several numerical examples. It is found that the nonlinear threshold accepting algorithm outperforms the genetic algorithm and ant colony system, while the genetic algorithm provides better results than the ant colony system for longer manufacturing lines.     

Optimization of maintenance policy using the proportional hazard model

The evolution of system reliability depends on its structure as well as on the evolution of its components reliability. The latter is a function of component age during a system's operating life. Component aging is strongly affected by maintenance activities performed on the system. In this work, we consider two categories of maintenance activities: corrective maintenance (CM) and preventive maintenance (PM). Maintenance actions are characterized by their ability to reduce this age. PM consists of actions applied on components while they are operating, whereas CM actions occur when the component breaks down. In this paper, we expound a new method to integrate the effect of CM while planning for the PM policy. The proportional hazard function was used as a modeling tool for that purpose. Interesting results were obtained when comparison between policies that take into consideration the CM effect and those that do not is established.     

Availability optimisation for stochastic degrading systems under imperfect preventive maintenance

This paper deals with imperfect preventive maintenance (PM) optimisation problem. The system to be maintained is typically a production system assumed to be continuously monitored and subject to stochastic degradation. To assess such degradation, the proposed maintenance model takes into account both corrective maintenance (CM) and PM. The system undergoes PM whenever its reliability reaches an appropriate value, while CM is performed at system failure. After a given number of maintenance actions, the system is preventively replaced by a new one. Both CM as well as PM are considered imperfect, i.e. they bring the system to an operating state which lies between two extreme states, namely the as bad as old state and as good as new state. The imperfect effect of CM and PM is modelled on the basis of the hybrid hazard rate model. The objective of the proposed PM optimisation model consists on finding the optimal reliability threshold together with the optimal number of PM actions to maximise the average availability of the system. A mathematical model is then proposed. To solve this problem an algorithm is provided. A numerical example is presented to illustrate the proposed maintenance optimisation model.     

Minmax defense strategy for complex multi-state systems

This paper presents a general optimization methodology that merges game theory and multi-state system survivability theory. The defender has multiple alternatives of defense strategy that presumes separation and protection of system elements. The attacker also has multiple alternatives of its attack strategy based on a combination of different possible attack actions against different groups of system elements. The defender minimizes, and the attacker maximizes, the expected damage caused by the attack (taking into account the unreliability of system elements and the multi-state nature of complex series-parallel systems). The problem is defined as a two-period minmax non-cooperative game between the defender who moves first and the attacker who moves second. An exhaustive minmax optimization algorithm is presented based on a double-loop genetic algorithm for determining the solution. A universal generating function technique is applied for evaluating the losses caused by system performance reduction. Illustrative examples with solutions are presented.     

Harmony search algorithm: application to the redundancy optimization problem

The redundancy optimization problem is a well known NP-hard problem which involves the selection of elements and redundancy levels to maximize system performance, given different system-level constraints. This article presents an efficient algorithm based on the harmony search algorithm (HSA) to solve this optimization problem. The HSA is a new nature-inspired algorithm which mimics the improvization process of music players. Two kinds of problems are considered in testing the proposed algorithm, with the first limited to the binary series–parallel system, where the problem consists of a selection of elements and redundancy levels used to maximize the system reliability given various system-level constraints; the second problem for its part concerns the multi-state series–parallel systems with performance levels ranging from perfect operation to complete failure, and in which identical redundant elements are included in order to achieve a desirable level of availability. Numerical results for test problems from previous research are reported and compared. The results of HSA showed that this algorithm could provide very good solutions when compared to those obtained through other approaches.