Optimization of Preventive Maintenance in Chemical Process Plants

In this article, we use a genetic algorithm to obtain an economically optimal preventive maintenance frequency for different equipment, the parts inventory policy (number and type of spare parts to keep in stock), and labor allocation in process plants. To assess cost, we improved a previously published Monte Carlo simulation-based maintenance model (Nguyen et al. Ind. Eng. Chem. Res. 2008, 47(6), 1910−1924). Two examples, a Tennessee Eastman example and a fluid catalytic cracking unit in a refinery, are provided.

[1]  Luca Podofillini,et al.  Multiobjective spare part allocation by means of genetic algorithms and Monte Carlo simulation , 2005, Reliab. Eng. Syst. Saf..

[2]  Received for review , 1975 .

[3]  Luca Podofillini,et al.  Condition-based maintenance optimization by means of genetic algorithms and Monte Carlo simulation , 2002, Reliab. Eng. Syst. Saf..

[4]  Garrison W. Greenwood,et al.  Workforce-constrained Preventive Maintenance Scheduling Using Evolution Strategies , 2000, Decis. Sci..

[5]  M.C. Fu,et al.  Optimal preventive maintenance scheduling in semiconductor manufacturing , 2004, IEEE Transactions on Semiconductor Manufacturing.

[6]  Miguel J. Bagajewicz,et al.  New Tool for the Evaluation of the Scheduling of Preventive Maintenance for Chemical Process Plants , 2008 .

[7]  Enrico Zio,et al.  Optimizing maintenance and repair policies via a combination of genetic algorithms and Monte Carlo simulation , 2000, Reliab. Eng. Syst. Saf..

[8]  Glenn R. Hinchcliffe,et al.  RCM--Gateway to World Class Maintenance , 2003 .

[9]  Xiaodong Yao,et al.  Optimal Preventive Maintenance Scheduling in Semiconductor Manufacturing Systems: Software Tool and Simulation Case Studies , 2010, IEEE Transactions on Semiconductor Manufacturing.

[10]  Serge Domenech,et al.  Optimization of preventive maintenance strategies in a multipurpose batch plant: application to semiconductor manufacturing , 2003, Comput. Chem. Eng..

[11]  Sophie Mercier.  A preventive maintenance policy with sequential checking procedure for a Markov deteriorating system , 2002, Eur. J. Oper. Res..

[12]  Frank P. Lees,et al.  Loss Prevention In The Process Industries , 1980 .

[13]  Amik Garg,et al.  Maintenance management: literature review and directions , 2006 .

[14]  Andrej Atrens,et al.  Strategic maintenance management , 2002 .

[15]  Semra Tunali,et al.  Joint optimization of spare parts inventory and maintenance policies using genetic algorithms , 2007 .

[16]  Hoang Pham,et al.  OPTIMAL AGE-DEPENDENT PREVENTIVE MAINTENANCE POLICIES WITH IMPERFECT MAINTENANCE , 1996 .

[17]  Chang Wook Ahn,et al.  On the practical genetic algorithms , 2005, GECCO '05.

[18]  W. J. Kennedy,et al.  An overview of recent literature on spare parts inventories , 2002 .

[19]  Haritha Saranga.  Opportunistic maintenance using genetic algorithms , 2004 .

[20]  Dah-Chuan Gong,et al.  The application of genetic algorithm in the development of preventive maintenance analytic model , 2007 .

[21]  Ruhul A. Sarker,et al.  Optimization of maintenance and spare provisioning policy using simulation , 2000 .

[22]  R. Keith Mobley,et al.  An introduction to predictive maintenance , 1989 .

[23]  Mark A. Kramer,et al.  A general framework for preventive maintenance optimization in chemical process operations , 1997 .

[24]  David M. Miller,et al.  Maximizing the Effectiveness of a Preventive Maintenance System: An Adaptive Modeling Approach , 1997 .

[25]  Dragan Savic,et al.  Optimal opportunistic maintenance policy using genetic algorithms, 1: formulation , 1995 .

[26]  Hongzhou Wang,et al.  A survey of maintenance policies of deteriorating systems , 2002, Eur. J. Oper. Res..

[27]  JayHyung Lee,et al.  Nonlinear modeling and state estimation for the Tennessee Eastman challenge process , 1995 .