Joint Optimization of Spare Parts and Condition Based Maintenance Using Monte Carlo Approach

Abstract

Today according to the competitive conditions, companies try to reduce their inventory level to diminish the costs. In companies inventory management and control should establish a balance between inventory level of spare parts, cost and the risk that arising from absence of part when is needed. It is clear that this level of spare parts inventory affected by facility characteristics and its reliabilities. As a whole in the various industries, maintenance policies and determination of spare parts inventory level individually performed. In this paper is used Monte Carlo simulation to combinatorial optimize the condition based maintenance activities and spare parts inventory. Used binary genetic algorithm to find the optimal values of decision variables. In this optimize policy inspection intervals (T), maximum of spare parts inventory(S), spare parts renewed order point(s), frontier erosion to perform preventive replacement(LP) and human resource required to performing corrective and preventive replacements(labor). In the case study for maintenance events simulation used the oil analysis database of a construction company that included about 8000 data of oil analysis. Intended Monte Carlo simulation and also genetic algorithm coded in Matlab Software and finally the result of simulation is brought.

Keywords

References

H. Wang, "A survey of maintenance policies of deteriorating systems", European Journal of Operational Research 139, p. 469–489, 2002.
 
M. Ben-Daya, S. Duffuaa and A. Raouf, "Maintenance, Modeling and Optimization", Kluwer Academic, 2000.
 
B. Castanier, A. Grall and C. Be´renguer, "A condition-based maintenance policy with non-periodic inspections for a two-unit series system", Reliability Engineering and System Safety 87, p. 109–120, 2005.
 
L. Dieulle, C. Be´renguer and A. Grall, "Sequential condition-based maintenance scheduling for a deteriorating system", European Journal of Operational Research 150, p. 451–461, 2003.
 
S. Amari and L. McLaughlin, "Optimal design of a condition-based maintenance model", In: Reliability and Maintainability, Annual Symposium, 2004.
 
C. Chen, Y. Chen and J. Yuan, "On a dynamic preventive maintenance policy for a system under inspection", Reliability Engineering and System Safety 80, p. 41–47, 2003.
 
M. Moustafa, E. Maksoud and S. Sadek, "Optimal major and minimal maintenance policies for deteriorating systems", Reliability Engineering and System Safety 83, p. 363–368, 2004.
 
W. Wang, "Modelling condition monitoring intervals: A hybrid of simulation and analytical approaches", Journal of the Operational Research Society 54, p. 273–282, 2003.
 
T. Dohi, N. Kaio and S. Osaki, "On the optimal ordering policies in maintenance theory: Survey and applications", Applied Stochastic Models and Data Analysis 14, p. 309–321, 1998.
 
S. Sheu and W. Griffith, "Optimal age-replacement policy with age-dependent minimal-repair and random-leadtime", IEEE Transaction on Reliability 50, p. 302–309, 2001.
 
S. Sheu and Y. Chien, "Optimal age-replacement policy of a system subject to shocks with random lead-time", European Journal of Operational Research 159, p. 132–144, 2004.
 
A. Brezavsˇcˇek and A. Hudoklin, "Joint optimization of block-replacement and periodic-review spare-provisioning policy", IEEE Transaction on Reliability 52, p. 112–117, 2003.
 
A. Chelbi and D. Ait-Kadi, "Spare provisioning strategy for preventively replaced systems subjected to random failure", International Journal of Production Economics 74, p. 183–189, 2001.
 
M. Marseguerra, E. Zio and L. Podofillini, "Multiobjective spare part allocation by means of genetic algorithms and Monte Carlo simulation", Reliability Engineering and System Safety 87, p. 325–335, 2005.
 
A. Kabir and A. Al-Olayan, "A stocking policy for spare part provisioning under age based preventive replacement", European Journal of Operational Research 90, p. 171–181, 1996.
 
H. Kawai, "An optimal ordering and replacement policy of a Markovian degradation system under complete observation", Journal of the Operational Research Society Japan 26, p. 279–292, 1983.
 
A. Grall, C. Be´renguer and L. Dieulle, "A condition-based maintenance policy for stochastically deteriorating systems", Reliability Engineering and System Safety 76, p. 167–180, 2002.
 
B. Castanier, A. Grall and C. Be´renguer, "A condition-based maintenance policy with non-periodic inspections for a two-unit series system", Reliability Engineering and System Safety 87, p. 109–120, 2005.
 
H. Liao, E. Elsayed and L. Chan, "Maintenance of continuously monitored degrading systems", European Journal of Operational Research 175(2), p. 821–835, 2006.
 
A. Jardine, D. Banjevic, M. Wiseman, S. Buck and T. Joseph, "Optimizing a mine haul truck wheel motors’ condition monitoring program: Use of proportional hazards modeling", p. 286–301, 2001.
 
W. Kennedy, J. Wayne Patterson and L. Fredendall, "An over view of recent literature on spare parts inventories", International Journal of Production Economics 76(2), p. 201–215, 2002.
 
R. Sarker and A. Haque, "Optimization of maintenance and spare provisioning policy using simulation", Applied Mathematical Modelling 24(10), p. 751–760, 2000.
 
N. Kumar Samal and D. Kumar Pratihar, "Joint optimization of preventive maintenance and spare parts inventory using genetic algorithms and particle swarm optimization algorithm", International Journal of Production Economics, p. 201–215, 2014.
 
S. Panagiotidou, "Joint optimization of spare parts ordering and maintenance policies for multiple identical items subject to silent failures", European Journal of Operational Research, p. 300–314, 2013.
 
M. Ali Ilgin and S. Tunali, "Joint optimization of spare parts inventory and maintenance policies using genetic algorithms", The International Journal of Advanced Manufacturing , p. 594–604, 2007.
 
W. Kolarik, "Performance reliability", Department of Industrial Engineering, Texas Tech University, 1988.
 
H. Lu, W. Kolarik and S. Lu, "Real-time performance reliability prediction", IEEE Transaction on Reliability 50, p. 353–357, 2001a.
 
A. Cohen, "Truncated and Censored Samples: Theory and Applications", New York: Marcel Dekker, 1992.
 
J. Lawless, "Statistical Models and Methods for Lifetime Data", Beijing (in Chinese): China Statistics Press, 1998.
 
A. Kabir and A. Al-Olayan, "Joint optimization of age replacement and continuous review spare provisioning policy", Inter national Journal of Operations and Production Management 14(7), p. 53–69, 1994.
 
M. Wiseman, "Optimizing condition based maintenance", Plant Engineering and Maintenance 23 , pp. 57-71, 2001.
 
[34] ج. بنکس و ک. جان، "شبیه­سازی سیستم­های گسسته-پیشامد"، ترجمه محلوجی. هاشم، تهران: مؤسسه انتشارات علمی دانشگاه صنعتی شریف، 1378.
M. Wiseman, "Optimizing condition based maintenance", Plant Engineering and Maintenance 23 , pp. 57-71, 2001.
 

Files

History

  • Receive Date: 05 July 2015
  • Revise Date: 01 September 2015
  • Accept Date: 12 September 2015
  • Publish Date: 21 September 2015

Share

How to cite

Statistics