Optimal maintenance strategy for systems with two failure modes

This paper considers a single-unit system subject to two types of failures: a traditional catastrophic failure and a two-stage delayed failure. Periodic inspections are carried out to identify the defective stage of the two-stage failure process, whereas preventive replacements are implemented to avoid any potential failure due to the catastrophic failure mode. We construct a basic maintenance model and then extend it to the cases of imperfect inspections (i.e., inspections that do not always notice a defective state). We analyze the renewal process of the system and establish the expected long-run cost rate (ELRCR). The optimal inspection period and preventive replacement interval are determined by minimizing the ELRCR. A case study on infusion pumps is presented to illustrate the proposed model.

[1]  I. Linkov,et al.  Integrating Risk and Resilience Approaches to Catastrophe Management in Engineering Systems , 2013, Risk analysis : an official publication of the Society for Risk Analysis.

[2]  Ata Allah Taleizadeh,et al.  Optimizing integrated manufacturing and products inspection policy for deteriorating manufacturing system with imperfect inspection , 2015 .

[3]  Way Kuo,et al.  Reliability modeling and preventive maintenance of load-sharing systemswith degrading components , 2016 .

[4]  Dragan Banjevic,et al.  Optimum inspection interval for a system under periodic and opportunistic inspections , 2012 .

[5]  Wenbin Wang,et al.  An overview of the recent advances in delay-time-based maintenance modelling , 2012, Reliab. Eng. Syst. Saf..

[6]  Phuc Do,et al.  Maintenance grouping for multi-component systems with availability constraints and limited maintenance teams , 2015, Reliab. Eng. Syst. Saf..

[7]  María Dolores Berrade,et al.  Modelling imperfect inspection over a finite horizon , 2013, Reliab. Eng. Syst. Saf..

[8]  Toshio Nakagawa,et al.  Optimal periodic and random inspections with first, last and overtime policies , 2015, Int. J. Syst. Sci..

[9]  D. G. Johnson,et al.  The Role and Effectiveness of Theories of Decision in Practice , 1977 .

[10]  G. B. Williams,et al.  A delay time multi-level on-condition preventive maintenance inspection model based on constant base interval risk—when inspection detects pending failure , 1997 .

[11]  Wenbin Wang.  An inspection model for a process with two types of inspections and repairs , 2009, Reliab. Eng. Syst. Saf..

[12]  Enrico Zio,et al.  Genetic algorithms for condition-based maintenance optimization under uncertainty , 2015, Eur. J. Oper. Res..

[13]  Shaomin Wu,et al.  An Inspection Model Subject to Small Stoppages and Hard Failures , 2014 .

[14]  Rui Peng,et al.  Delay-time-based preventive maintenance modelling for a production plant: a case study in a steel mill , 2015, J. Oper. Res. Soc..

[15]  W Wang,et al.  Modelling condition monitoring inspection using the delay-time concept , 1992 .

[16]  Adiel Teixeira de Almeida,et al.  A multi-criteria decision model to determine inspection intervals of condition monitoring based on delay time analysis , 2009, Reliab. Eng. Syst. Saf..

[17]  María Dolores Berrade,et al.  Maintenance scheduling of a protection system subject to imperfect inspection and replacement , 2012, Eur. J. Oper. Res..

[18]  David W. Coit,et al.  Reliability and maintenance modeling for systems subject to multiple dependent competing failure processes , 2010 .

[19]  Antoine Grall,et al.  Multi-level predictive maintenance for multi-component systems , 2015, Reliab. Eng. Syst. Saf..

[20]  Yada Zhu,et al.  Multi-stage optimization for periodic inspection planning of geo-distributed infrastructure systems , 2015, Eur. J. Oper. Res..

[21]  Gregory Levitin,et al.  Element maintenance and allocation for linear consecutively connected systems , 2012 .

[22]  Biswajit Sarkar,et al.  Product inspection policy for an imperfect production system with inspection errors and warranty cost , 2016, Eur. J. Oper. Res..

[23]  A. H. Christer,et al.  Refining the delay-time-based PM inspection model with non-negligible system downtime estimates of the expected number of failures , 2000 .

[24]  Alaa Chateauneuf,et al.  Maintenance planning under imperfect inspections of corroded pipelines , 2013 .

[25]  Roger Flage,et al.  A delay time model with imperfect and failure-inducing inspections , 2014, Reliab. Eng. Syst. Saf..

[26]  Terje Aven,et al.  A delay-time model with safety constraint , 2009, Reliab. Eng. Syst. Saf..

[27]  A. H. Christer,et al.  Developments in delay time analysis for modelling plant maintenance , 1999, J. Oper. Res. Soc..

[28]  Shaomin Wu,et al.  Optimization of maintenance policy under parameter uncertainty using portfolio theory , 2017 .

[29]  Min Xie,et al.  An imperfect maintenance policy for mission-oriented systems subject to degradation and external shocks , 2016, Comput. Ind. Eng..

[30]  Antoine Grall,et al.  Sequential condition-based maintenance scheduling for a deteriorating system , 2003, Eur. J. Oper. Res..

[31]  Xiao Liu,et al.  Condition-based maintenance for continuously monitored degrading systems with multiple failure modes , 2013 .

[32]  Shaomin Wu,et al.  Linking component importance to optimisation of preventive maintenance policy , 2016, Reliab. Eng. Syst. Saf..

[33]  David W. Coit,et al.  Establishment of the optimal time interval between periodic inspections for redundant systems , 2014, Reliab. Eng. Syst. Saf..

[34]  Hamid Reza Golmakani,et al.  Optimal non-periodic inspection scheme for a multi-component repairable system using A∗ search algorithm , 2012, Comput. Ind. Eng..

[35]  Franck Schoefs,et al.  Development of a two-stage inspection process for the assessment of deteriorating infrastructure , 2010, Reliab. Eng. Syst. Saf..

[36]  Wenbin Wang,et al.  An inspection model based on a three-stage failure process , 2011, Reliab. Eng. Syst. Saf..