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.     

Reliability assessment of embedded digital system using multi-state function

This work describes a combinatorial model for estimating the reliability of the embedded digital system by means of multi-state function. This model includes a coverage model for fault-handling techniques implemented in digital systems. The fault-handling techniques make it difficult for many types of components in digital system to be treated as binary state, good or bad. The multi-state function provides a complete analysis of multi-state systems as which the digital systems can be regarded. Through adaptation of software operational profile flow to multi-state function, the HW/SW interaction is also considered for estimation of the reliability of digital system. Using this model, we evaluate the reliability of one board controller in a digital system, Interposing Logic System (ILS), which is installed in YGN nuclear power units 3 and 4. Since the proposed model is a generalized combinatorial model, the simplification of this model becomes the conventional model that treats the system as binary state. This modeling method is particularly attractive for embedded systems in which small sized application software is implemented since it will require very laborious work for this method to be applied to systems with large software.     

Estimation of the importance measures of multi-state elements by Monte Carlo simulation

A generalization of some frequently used importance measures has been proposed by some of the authors for application to multi-state systems constituted by multi-state elements. This paper deals with the Monte Carlo (MC) estimation of these measures, which entails evaluating the system output performance under restrictions on the performance levels of its multi-state elements. Simulation procedures are proposed according to two different performance-restriction approaches. Further, the flexibility of the MC method is exploited to account for load-sharing and operational dependencies among parallel elements. The approach is tested on a multi-state transmission system of literature.     

Multi-State Consecutive- k -out-of- n Systems

In the binary context, a consecutive- k -out-of- n system is failed if and only if at least k consecutive components are failed. In this paper we propose definitions of the multi-state consecutive- k -out-of- n :F and G systems. In the proposed definition, both the system and its components may be in one of M + 1 possible states: 0, 1,..., and M . The dual relationship between the proposed systems is identified. The concept of dominance is used to characterize the properties of multi-state systems. The concepts of duality, equivalence, and dominance are used in evaluation of system state distribution of multi-state consecutive- k -out-of- n systems. An algorithm is provided for evaluating system state distribution of decreasing multi-state consecutive- k -out-of- n :F systems. Another algorithm is provided to bound system state distribution of multi-state consecutive- k -out-of- n :F and G systems. Several examples are included to illustrate the proposed definitions, concepts, and algorithms.     

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.     

Comment on “A framework to practical predictive maintenance modeling for multi-state systems” by Tan C.M. and Raghavan N. [Reliab Eng Syst Saf 2008;93(8):1138-50]

“System-perspective” proposed by “A framework to practical predictive maintenance modeling for multi-state systems” by Tan C.M. and Raghavan N. [A framework to practical predictive maintenance modeling for multi-state systems. Reliab Eng Syst Saf 2008;93(8):1138-50] is a very useful method to evaluate and optimize the maintenance strategy for complex systems, especially for multi-state systems (MSS). The commented paper proposes an innovative process and modeling method to present imperfect maintenance effects on MSS, but there exist some incorrect points and misunderstandings. In this paper, these problems are pointed out and are attempted to be corrected under the original framework of the commented paper.     

An evaluation of the multi-state node networks reliability using the traditional binary-state networks reliability algorithm

A system where the components and system itself are allowed to have a number of performance levels is called the Multi-state system (MSS). A multi-state node network (MNN) is a generalization of the MSS without satisfying the flow conservation law. Evaluating the MNN reliability arises at the design and exploitation stage of many types of technical systems. Up to now, the known existing methods can only evaluate a special MNN reliability called the multi-state node acyclic network (MNAN) in which no cyclic is allowed. However, no method exists for evaluating the general MNN reliability. The main purpose of this article is to show first that each MNN reliability can be solved using any the traditional binary-state networks (TBSN) reliability algorithm with a special code for the state probability. A simple heuristic SDP algorithm based on minimal cuts (MC) for estimating the MNN reliability is presented as an example to show how the TBSN reliability algorithm is revised to solve the MNN reliability problem. To the author's knowledge, this study is the first to discuss the relationships between MNN and TBSN and also the first to present methods to solve the exact and approximated MNN reliability. One example is illustrated to show how the exact MNN reliability is obtained using the proposed algorithm.     

Reliability estimation and prediction of multi-state components and coherent systems

This paper discusses the multi-state coherent system composed of multi-state components. First, using the min cut sets or min path sets, we present our simulation algorithm, instead of the general structure function, to calculate the probability that the system is in a specified state. Second, we check the components per period, e.g. one check per year, to obtain the state sequences of all components. When the state sequences are Markovian chains, we can predict the reliability of the components in several periods, such as the probability that the components are in specified states. Also, we give two methods to compute the system reliability in a number of periods: one employs the states of the components in these periods, which can be predicted by the state transition probability matrixes of the components; the other uses the state transition probability matrix of the system obtained by the simulated states of the components.     

Simulation platform for anticipative plant-level maintenance decision support system

Global competition and increasing customer expectations are forcing automobile manufacturers to improve their operations. Maintenance, being one of the most critical components in many industries, has a direct impact on the improvement of the overall production performance. In this paper, we introduce an anticipative plant-level maintenance decision support system (APMDSS) that provides guidance on corrective and preventive maintenance priorities based on the equipment bottleneck ranks with the objective of improving daily plant throughput. APMDSS anticipates the plant dynamics (i.e. bottlenecks, hourly buffer levels and likelihood of machine breakdowns) for upcoming shifts using starting state information of the production shift (e.g. equipment maintenance history, operational status of machines, buffer levels and scheduled production model mix). We also evaluate the performance of APMDSS using real data from an automotive body shop experiencing routine throughput difficulties due to frequent machine breakdowns. The results are compared with other methods from the literature and found to be superior in many settings.     

Multi-state component criticality analysis for reliability improvement in multi-state systems

This paper evaluates and implements composite importance measures (CIM) for multi-state systems with multi-state components (MSMC). Importance measures are frequently used as a means to evaluate and rank the impact and criticality of individual components within a system yet they are less often used as a guide to prioritize system reliability improvements. For multi-state systems, previously developed measures sometimes are not appropriate and they do not meet all user needs. This study has two inter-related goals: first, to distinguish between two types of importance measures that can be used for evaluating the criticality of components in MSMC with respect to multi-state system reliability, and second, based on the CIM, to develop a component allocation heuristic to maximize system reliability improvements. The heuristic uses Monte-Carlo simulation together with the max-flow min-cut algorithm as a means to compute component CIM. These measures are then transformed into a cost-based composite metric that guides the allocation of redundant elements into the existing system. Experimental results for different system complexities show that these new CIM can effectively estimate the criticality of components with respect to multi-state system reliability. Similarly, these results show that the CIM-based heuristic can be used as a fast and effective technique to guide system reliability improvements.     

A joint reliability-redundancy optimization approach for multi-state series-parallel systems

In this paper, we present a practical approach for the joint reliability-redundancy optimization of multi-state series-parallel systems. In addition to determining the optimal redundancy level for each parallel subsystem, this approach also aims at finding the optimal values for the variables that affect the component state distributions in each subsystem. The key point is that technical and organizational actions can affect the state transition rates of a multi-state component, and thus affect the state distribution of the component and the availability of the system. Taking this into consideration, we present an approach for determining the optimal versions and numbers of components and the optimal set of technical and organizational actions for each subsystem of a multi-state series-parallel system, so as to minimize the system cost while satisfying the system availability constraint. The approach might be considered to be the multi-state version of the joint system reliability-redundancy optimization methods.     

Redundancy analysis for repairable multi-state system by using combined stochastic processes methods and universal generating function technique

This paper discusses a type of redundancy that is typical in a multi-state system. It considers two interconnected multi-state systems where one multi-state system can satisfy its own stochastic demand and also can provide abundant resource (performance) to another system in order to improve the assisted system reliability. Traditional methods are usually not effective enough for reliability analysis for such multi-state systems because of the “dimensional curse” problem. This paper presents a new method for reliability evaluation for the repairable multi-state system considering such kind of redundancy. The proposed method is based on the combination of the universal generating function technique and random processes methods. The numerical example is presented to illustrate the proposed method.     

New insights on multi-state component criticality and importance

In this paper, new importance measures for multi-state systems with multi-state components are introduced and evaluated. These new measures complement and enhance current work done in the area of multi-state reliability. In general, importance measures are used to evaluate and rank the criticality of component or component states with respect to system reliability. The focus of the study is to provide intuitive and clear importance measures that can be used to enhance system reliability from two perspectives: (1) how a specific component affects multi-state system reliability and (2) how a particular component state or set of states affects multi-state system reliability. The first measure unsatisfied demand index, provides insight regarding a component or component state contribution to unsatisfied demand. The second measure multi-state failure frequency index, elaborates on an approach that quantifies the contribution of a particular component or component state to system failure. Finally, the multi-state redundancy importance identifies where to allocate component redundancy as to improve system reliability. The findings of this study indicate that both perspectives can be used to complement each other and as an effective tool to assess component criticality. Examples illustrate and compare the proposed measures with previous multi-state importance measures.     

Monte Carlo simulation analysis of the effects of different system performance levels on the importance of multi-state components

In the present paper, we consider some frequently used importance measures, in their generalized form proposed by the authors for application to multi-state systems constituted by multi-state components. To catch the dynamics of multi-state systems, Monte Carlo simulation has been utilized. A simulation approach has been presented which allows estimating of all the importance measures of the components at a given performance level in a single simulation, provided that the components are independent. The effects of different performance demands made on the system on the importance of its multi-state components have been examined with respect to a simple multi-state series–parallel system. The results have shown that a performance level of a component may be more critical for the achievement of a system performance and less critical for another.     

Advanced DAG-Based Ranking (ADR) Protocol for Blockchain Scalability

In the past decade, blockchain has evolved as a promising solution to develop secure distributed ledgers and has gained massive attention. However, current blockchain systems face the problems of limited throughput, poor scalability, and high latency. Due to the failure of consensus algorithms in managing nodes’identities, blockchain technology is considered inappropriate for many applications, e.g., in IoT environments, because of poor scalability. This paper proposes a blockchain consensus mechanism called the Advanced DAG-based Ranking (ADR) protocol to improve blockchain scalability and throughput. The ADR protocol uses the directed acyclic graph ledger, where nodes are placed according to their ranking positions in the graph. It allows honest nodes to use the Direct Acyclic Graph (DAG) topology to write blocks and verify transactions instead of a chain of blocks. By using a three-step strategy, this protocol ensures that the system is secured against doublespending attacks and allows for higher throughput and scalability. The first step involves the safe entry of nodes into the system by verifying their private and public keys. The next step involves developing an advanced DAG ledger so nodes can start block production and verify transactions. In the third step, a ranking algorithm is developed to separate the nodes created by attackers. After eliminating attacker nodes, the nodes are ranked according to their performance in the system, and true nodes are arranged in blocks in topological order. As a result, the ADR protocol is suitable for applications in the Internet of Things (IoT). We evaluated ADR on EC2 clusters with more than 100 nodes and achieved better transaction throughput and liveness of the network while adding malicious nodes. Based on the simulation results, this research determined that the transaction’s performance was significantly improved over blockchains like Internet of Things Applications (IOTA) and ByteBall.     

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.     

Reliability and risk analysis of large systems with ageing components

Applications of limit reliability functions to the reliability evaluation of large multi-state systems composed of independent components are considered. The main emphasis is on multi-state systems with ageing components because of the importance of such an approach in safety analysis, assessment and prediction, and analysing the effectiveness of operation processes of real technical systems. The results concerned with multi-state series systems are applied to the reliability evaluation and risk function determination of a homogeneous bus transportation system. Results on limit reliability functions of a homogeneous multi-state “m out of n” system are applied to durability evaluation of a steel rope. A non-homogeneous series-parallel pipeline systems composed of several lines of pipe segments is estimated as well. Moreover, the reliability evaluation of the model homogeneous parallel-series electrical energy distribution system is performed.     

A heuristic for solving the redundancy allocation problem for multi-state series-parallel systems

The redundancy allocation problem is formulated with the objective of minimizing design cost, when the system exhibits a multi-state reliability behavior, given system-level performance constraints. When the multi-state nature of the system is considered, traditional solution methodologies are no longer valid. This study considers a multi-state series-parallel system (MSPS) with capacitated binary components that can provide different multi-state system performance levels. The different demand levels, which must be supplied during the system-operating period, result in the multi-state nature of the system. The new solution methodology offers several distinct benefits compared to traditional formulations of the MSPS redundancy allocation problem. For some systems, recognizing that different component versions yield different system performance is critical so that the overall system reliability estimation and associated design models the true system reliability behavior more realistically. The MSPS design problem, solved in this study, has been previously analyzed using genetic algorithms (GAs) and the universal generating function. The specific problem being addressed is one where there are multiple component choices, but once a component selection is made, only the same component type can be used to provide redundancy. This is the first time that the MSPS design problem has been addressed without using GAs. The heuristic offers more efficient and straightforward analyses. Solutions to three different problem types are obtained illustrating the simplicity and ease of application of the heuristic without compromising the intended optimization needs.     

A framework to practical predictive maintenance modeling for multi-state systems

A simple practical framework for predictive maintenance (PdM)-based scheduling of multi-state systems (MSS) is developed. The maintenance schedules are derived from a system-perspective using the failure times of the overall system as estimated from its performance degradation trends.

The system analyzed in this work is a flow transmission water pipe system. The various factors influencing PdM-based scheduling are identified and their impact on the system reliability and performance are quantitatively studied. The estimated times to replacement of the MSS may also be derived from the developed model.

The results of the model simulation demonstrate the significant impact of maintenance quality and the criteria for the call for maintenance (user demand) on the system reliability and mean performance characteristics. A slight improvement in maintenance quality is found to postpone the system replacement time by manifold. The consistency in the quality of maintenance work with minimal variance is also identified as a very important factor that enhances the system's future operational and downtime event predictability.

The studies also reveal that in order to reduce the frequency of maintenance actions, it is necessary to lower the minimum user demand from the system if possible, ensuring at the same time that the system still performs its intended function effectively.

The model proposed can be utilized to implement a PdM program in the industry with a few modifications to suit the individual industrial systems’ needs.     

Estimation of boundary points for continuum-state system reliability measures

A continuum-state system is considered, in which the performance levels of the system and its components range from perfect functionality to complete failure, allowing any intermediate state in the arbitrary interval. A number of recent papers on general continuum-state system reliability are briefly reviewed. A new approach based on the universal generating function technique is suggested for estimating boundary points of several reliability measures for such systems. It is shown, how the continuum-state system can be approached by using a finite multi-state system and how the bounds for the reliability measures may be found. The suggested procedure for estimating boundary points enables the engineer to base only on a representation of an ordinary system logic diagram. Using formal procedures, one can get upper and lower bounds for the entire continuum-state system reliability measures with preliminary specified accuracy. A numerical example for the suggested approach is presented.