The Application of Genetic Algorithm to the Optimization of the Maintenance Schedule at a Certain Level of availability and reliability: Case study Cathodic Protection System of Gas Distribution Steel Network

Document Type : Research Paper

Authors

Department of Industrial Engineering, Faculty of Engineering, University of Kurdistan, Sanandaj, Iran.

Abstract

This paper presented a preventive maintenance scheduling model to optimize the cost and improve the effective age of machines in complex repairable systems. The objective function of the developed model is to minimize the total maintenance costs while maintaining a defined level of availability and reliability. The maintenance costs include random failure cost, repair cost, replacement cost, and total planned downtime cost. Multilevel preventive maintenance actions such as inspection, repair and replacement are considered through the whole planning horizon. A metaheuristic algorithm like genetic algorithm (GA) was developed using a MATLAB program to provide a near-optimal solution for the optimization model. The proposed mathematical model was applied to a Cathodic Protection System of Gas Distribution Steel Network and the results show a reduction in the total maintenance cost by 36%.

Keywords

Main Subjects

[1]          I. A. Kattan, A. K. Hassan, A case study on improving the effectiveness of preventive maintenance, International Journal of Management Science and Engineering Management, Vol. 5, No. 5, pp. 353-361, 2010.
[2]          I. H. Afefy, Maintenance planning based on computer-aided preventive maintenance policy, in Proceeding of.
[3]          M. Zhao, Availability for repairable components and series systems, IEEE Transactions on Reliability, Vol. 43, No. 2, pp. 329-334, 1994.
[4]          S. Dellagi, N. Rezg, A. Gharbi, Optimal maintenance/production policy for a manufacturing system subjected to random failure and calling upon several subcontractors, International Journal of Management Science and Engineering Management, Vol. 5, No. 4, pp. 261-267, 2010.
[5]          I. Maatouk, N. Chebbo, E. Châtelet, I. Jarkass, Preventive maintenance optimization for multi states series-parallel systems, in Proceeding of, 220-226.
[6]          M. Doostparast, F. Kolahan, M. Doostparast, Optimisation of PM scheduling for multi-component systems–a simulated annealing approach, International Journal of Systems Science, Vol. 46, No. 7, pp. 1199-1207, 2015.
[7]          L. Yang, Z.-s. Ye, C.-G. Lee, S.-f. Yang, R. Peng, A two-phase preventive maintenance policy considering imperfect repair and postponed replacement, European Journal of Operational Research, Vol. 274, No. 3, pp. 966-977, 2019.
[8]          M. Heydari, Two-stage failure modeling and optimal periodic inspection policy during the extended warranty period, International Journal of Management Science and Engineering Management, Vol. 14, No. 4, pp. 264-272, 2019.
[9]          K. S. Moghaddam, J. S. Usher, Optimal preventive maintenance and replacement schedules with variable improvement factor, Journal of Quality in Maintenance Engineering, Vol. 16, No. 3, pp. 271-287, 2010.
[10]        M. Shalaby, A. Gomaa, A. Mohib, A genetic algorithm for preventive maintenance scheduling in a multiunit multistate system, Journal of Engineering and Applied Science, Vol. 51, No. 4, pp. 795-811, 2004.
[11]        E. Silva, M. Morozowski, L. Fonseca, G. Oliveira, A. Melo, J. Mello, Transmission constrained maintenance scheduling of generating units: a stochastic programming approach, IEEE Transactions on Power Systems, Vol. 10, No. 2, pp. 695-701, 1995.
[12]        M. Choulaie, A. Bagheri, A. Khademifar, Nonlinear vibration and stability analysis of beam on the variable viscoelastic foundation, Journal of Computational Applied Mechanics, Vol. 48, No. 1, pp. 99-110, 2017.
[13]        S. M. Metwalli, M. S. Salama, R. A. Taher, Computer aided reliability for optimum maintenance planning, Computers & industrial engineering, Vol. 35, No. 3-4, pp. 603-606, 1998.
[14]        A. Tam, W. M. Chan, J. W. H. Price, Optimal maintenance intervals for a multi-component system, Production Planning and Control, Vol. 17, No. 8, pp. 769-779, 2006.
[15]        G. Levitin, A. Lisnianski, Short communication optimal replacement scheduling in multiā€state series–parallel systems, Quality and Reliability Engineering International, Vol. 16, No. 2, pp. 157-162, 2000.
[16]        F. Pargar, O. Kauppila, J. Kujala, Integrated scheduling of preventive maintenance and renewal projects for multi-unit systems with grouping and balancing, Computers & Industrial Engineering, Vol. 110, pp. 43-58, 2017.
[17]        R. Manzini, R. Accorsi, T. Cennerazzo, E. Ferrari, F. Maranesi, The scheduling of maintenance. A resource-constraints mixed integer linear programming model, Computers & Industrial Engineering, Vol. 87, pp. 561-568, 2015.
[18]        H. Lee, J. H. Cha, New stochastic models for preventive maintenance and maintenance optimization, European Journal of Operational Research, Vol. 255, No. 1, pp. 80-90, 2016.
[19]        P. Boonyathap, J. Jaturonnatee, Multiple periodic preventive maintenance for used equipment under lease, in Proceeding of.
[20]        H. Peng, Q. Zhu, Approximate evaluation of average downtime under an integrated approach of opportunistic maintenance for multi-component systems, Computers & Industrial Engineering, Vol. 109, pp. 335-346, 2017.
[21]        J. S. Usher, A. H. Kamal, W. H. Syed, Cost optimal preventive maintenance and replacement scheduling, IIE transactions, Vol. 30, No. 12, pp. 1121-1128, 1998.
[22]        I. B. Salehpoor, S. Molla-Alizadeh-Zavardehi, A constrained portfolio selection model at considering risk-adjusted measure by using hybrid meta-heuristic algorithms, Applied Soft Computing, Vol. 75, pp. 233-253, 2019.
[23]        R. Bris, E. Châtelet, F. Yalaoui, New method to minimize the preventive maintenance cost of series–parallel systems, Reliability engineering & system safety, Vol. 82, No. 3, pp. 247-255, 2003.
[24]        Y.-T. Tsai, K.-S. Wang, H.-Y. Teng, Optimizing preventive maintenance for mechanical components using genetic algorithms, Reliability engineering & system safety, Vol. 74, No. 1, pp. 89-97, 2001.
[25]        H. Javanmard, A. a.-W. Koraeizadeh, Optimizing the preventive maintenance scheduling by genetic algorithm based on cost and reliability in National Iranian Drilling Company, Journal of Industrial Engineering International, Vol. 12, pp. 509-516, 2016.
[26]        M. Choulaei, A.-H. Bouzid, Stress analysis of bolted flange joints with different shell connections, in Proceeding of, American Society of Mechanical Engineers, pp. V012T12A029.
[27]        M. Choulaei, Stress analysis of bolted flange joints with different shell connections,  Thesis, École de technologie supérieure, 2022.
[28]        S. Kumhar, M. Kumar, Generator maintenance scheduling of power system using hybrid, International Research Journal of Engineering and Technology, Vol. 3, pp. 418-423, 2016.
[29]        P. P. Tambe, Optimization based on Genetic Algorithm for maintenance decision of multi-unit system, in Proceeding of, IEEE, pp. 1-5.
[30]        N. Yousefi, D. W. Coit, X. Zhu, Dynamic maintenance policy for systems with repairable components subject to mutually dependent competing failure processes, Computers & Industrial Engineering, Vol. 143, pp. 106398, 2020.
[31]        L. Crow, Reliability Analysis for Complex, Repairable Systems. Army Materiel Systems Analysis Activity & AMSAA, Technical report,  pp. 1975.
[32]        J. M. Gannon, K. Kang, Forecasting overhaul or replacement intervals based on estimated system failure intensity,  Thesis, Naval Postgraduate School, 1994.
Volume 54, Issue 3
September 2023
Pages 455-466
  • Receive Date: 05 May 2023
  • Revise Date: 10 September 2023
  • Accept Date: 28 September 2023