Maintenance, Modeling and Optimization

480 Pages·2000·14.204 MB·English

by  M. Ben-Daya, S. O. Duffuaa (auth.), Mohamed Ben-Daya, Salih O. Duffuaa, Abdul Raouf (eds.)

MAINTENANCE, MODELING
AND
OPTIMIZATION
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ISBN 978-1-4613-6944-8 ISBN 978-1-4615-4329-9 (eBook)
DOI 10.1007/978-1-4615-4329-9
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Contents
List of Figures xi
List of Tables xvi
Preface xvii
Acknowledgment xxi
Contributing Authors xxiii
Part I INTRODUCTION
1
Maintenance Modeling Areas 3
M. Ben-Daya and S. O. Duffuaa
1. Introduction 3
2. Maintenance Policies 4
3. Maintenance Planning and Scheduling 14
4. Spare Parts Provisioning 17
5. Integrated Models 23
6. Future Research Directions 26
Part II MAINTENANACE PLANNING & SCHEDULING
2
Mathematical Models in Maintenance Planning and 39
Scheduling
Salih O. Duffuaa
1. Introduction 39
2. Maintenance Capacity Planning 40
3. Allocation of Resources 44
4. Scheduling Preventive Maintenance 45
5. Scheduling Maintenance Jobs 46
v
vi MAINTENANCE, MODELING AND OPTIMIZATION
6. Conclusion and Further Research 52
3
Electric Generator Maintenance Scheduling 55
Ibrahim El-Amin
1. Introduction 56
2. Maintenance Goals and Model Formulation 58
3. Solution Methods 69
4. The Application of Fuzzy Systems to the GMS Problem 75
5. The Integrated Generation & Transmission Maintenance Sched-
ro
~
6. Conclusions 77
4
Reliability Based Spare Parts Forecasting and Pro- 81
curement Strategies
A. K. Sheikh, M. Younas and A. Raoul
1. Introduction 82
2. Scope of the Work 84
3. Reliability Characteristics of the Unit 86
4. Spare Parts Calculations for Failure Replacement 90
5. Spare Part Calculations for Scheduled Replacements 96
6. Purchasing and Maintenance Link 98
7. Spare Part Classification 99
8. Practical Spare Parts Management 100
9. Extending the Ideas to Repairable Systems 106
10. Concluding Remarks 107
5
Maintenance Service Contracts 111
D. N. P. Murthy
1. Introduction 111
2. Maintenance 113
3. Warranty and Extended Warranty 115
4. Maintenance Service Contracts 120
5. Mathematical Modeling of Service Contracts 124
6. Conclusions and Topics of Future Research 130
6
Simulation Metamodeling of a Maintenance Float System 133
Christian N. Madu
1. Introduction 133
2. Maintenance Float Systems 135
3. The Metamodel 141
4. Cost Optimization 146
5. Steps for Developing a Metamodel 148
6. Conclusion 149
Part III PREVENTIVE MAINTENANCE
7
Basic Preventive Maintenance Policies and their Variations 155
Contents vii
T. Dohi, N. Kaio, and S. Osaki
1. Introduction. 155
2. Mathematical Preliminaries 157
3. Block Replacement 162
4. Age Replacement 168
5. Order Replacement 173
6. Conclusion 177
8
A General Framework for Analyzing Maintenance Policies 185
V. Makis, X Jiang, A.K.S. Jardine and K. Cheng
1. Introduction 186
2. Background 186
3. The Average Cost Optimal Policy for a Repair/Replacement
Problem 189
4. Optimal Policy in the Discounted Cost Case 195
9
Imperfect Preventive Maintenance Models 201
Toshio Nakagawa
1. Introduction 201
2. Analysis of Policy 1 203
3. Analysis of Policy 2 206
4. Analysis of Policy 3 209
5. Conclusions 211
10
Single Machine Inspection Problem 215
Moncer Hanga Mohammad A. AI-Fawzan
1. Introduction 216
2. Notation, Assumptions, and Preliminary Results 217
3. Infinite Horizon Model 220
4. Finite Horizon Model with Continuous Inspection Times 231
5. Finite Horizon Model with Discrete Inspection Time 237
6. Random Horizon Model 239
7. Conclusions 241
11
A General Approach for the Coordination of Mainte- 245
nance Frequencies
R. Dekker, R.E. Wildeman, J.B. G. Frenk and R. Van Egmond
1. Introduction 245
2. Problem Definition 247
3. Analysis of the Problem 250
4. Solving Problem (Q) 256
5. Numerical Results 268
6. Conclusions 272
12
Maintenance Grouping in Production Systems 283
Gerhard van Dijkhuizen
1. Introduction 283
viii MAINTENANCE, MODELING AND OPTIMIZATION
2. Literature Review 287
3. A Multi-Setup Multi-Component Production System 290
4. Modeling Framework 293
5. A Mixed Integer Linear Programming Formulation 297
6. An Illustrative Example 300
7. Concluding Remarks 301
Part IV CONDITION BASED MAINTENANCE
13
On-Line Surveillance and Monitoring 309
Hai S. Jeong Elsayed A. Elsayed
1. Introduction 309
2. Reliability Prediction and The Limit Value Determination in
Condition Monitoring 311
3. Vibration Monitoring 317
4. Sound Recognition and Acoustic Emission 325
5. Temperature Monitoring 330
6. Fluid Monitoring 331
7. Corrosion Monitoring 333
8. New Approaches in Condition Monitoring 333
9. Conclusions 336
14
Maintenance Scheduling Using Monitored Parameter 345
Values
Dhananjay Kumar
1. Introduction 346
2. Reliability Models 347
3. Proportional Hazards Model 348
4. Proportional Intensity Model 349
5. Accelerated Failure Time Models 351
6. Some Other Models 351
7. Selection of Models 352
8. Maintenance Scheduling under the Age Replacement Policy 353
9. Total Time on Test (TTT)-Plotting 355
10. Example 358
11. Maintenance Scheduling under the Block replacement Policy 362
12. Example 364
13. Conclusions 370
Part V INTEGRATED MAINTENANCE, PRODUCTION AND
QUALITY MODELS
15
A General EMQ Model with Machine Breakdowns 377
V. Makis, X. Jiang and E. Tse
1. Introduction 378
2. Model Description 380
3. The Structure of the Optimal Policy 380
4. An EMQ Model With Lost Sales 383
5. Numerical Example 388
Contents ix
6. Model With Preventive Replacement After the First Produc-
tion Run 394
7. Conclusions 395
16
Stochastic Manufacturing Systems: Production and 397
Maintenance Control
E. K. Boukas Q. Zhang
1. Introduction 397
2. Production Control Problem 399
3. Production and Corrective Maintenance Control 414
4. Production and Preventive Maintenance Control 419
5. Numerical Methods and Examples 422
6. Conclusion 428
Part VI MAINTENANCE & NEW TECHNOLOGIES
17
JIT and Maintenance 439
G. Waeyenbergh, L. Pintelon, and L. Gelders
1. Introduction 440
2. The JIT-Philosophy 440
3. Maintenance Meets Production 441
4. From Preventive Maintenance to Productive Maintenance 444
5. The TPM-Philosophy 445
6. The Pillars of TPM 447
7. The Need for Supporting Maintenance Concepts 450
8. The Ideal Base to Start With TPM 455
9. Modeling Tools for Improved Maintenance 457
10. Illustrative case: Failure Analysis and TPM in a Brewery 465
11. Conclusions 467
Index 471
List of Figures
2.1 Classification of maintenance planning and scheduling. 41
4.1 The relationship between the coefficient of variation
K = a I J.L and shape parameter,,8 of the Weibull
model [,8 = 11K]. 88
4.2 Failure rate function of Weibull modelfor ,8 = 1,,8 <
1 and,8 > 1. 89
4.3 Probability density function of Weibull model for
,8 = 1 (constant failure rate), ,8 < 1 (decreasing fail-
ure rate) and ,8 > 1 (increasing failure rate). 89
4.4 Weibull reliability analysis of 54 extrusion eies life
:die life Xi is expressed as Kg of metal extruded until
failure. 91
4.5 One realization of renewal or counting process of
part replacement 91
4.6 Renewal function of Weibull model. 93
4.7 Renewal rate function of Weibull model. 94
4.8 Variance of number of renewals for Weibull model. 94
4.9 Illustration of inventory model and related variables. 102
4.10 Effect of normal demand during lead time. 103
5.1 Customer's optimal strategies. 127
6.1 Maintenance float network. 136
6.2 Metamodel construction procedure. 139
8.1 The optimal repair cost limit. 196
10.1 Cash flow structure over one cycle 219
10.2 Graphical form of P (T, 00). 222
Xll MAINTENANCE, MODELING AND OPTIMIZATION
11.1 An example of the function gi (. ). The thin lines are
the graphs of the functions <I>i (lit), <I>i (2/t), ... , <I>i (5 It).
The (bold) graph of gi(·) is the lower envelope of
these functions. 278
11.2 An example of the objective function of problem (Q).
There are three local minima: at Tl, T2 and T3. 278
11.3 An example of the function g;R)(.). Notice the sim-
ilarity with the graph of gi(·) in Figure 11.1. 279
11.4 An example of the objective function of problem (R). 279
12.1 Maintenance initiators, activities, and packages: an
overall perspective. 284
12.2 Tree-like structure of set-up activities and mainte-
nance jobs (example). 291
12.3 Multiple interrelated set-up and maintenance activ-
ities with associated costs for a tramcar (Sculli and
Suraweera, 1979). 292
12.4 How to create maintenance opportunities from main-
tenance frequencies ( example). 301
13.1 Fatigue-crack-growth data from Bogdanoff and Kozin
(1985). 312
13.2 f(x; t) versus t for MIDP. 313
13.3 Ball bearing rotation. 320
13.4 Outer race defect. The ball pass frequency on the
outer race is 172 Hz. The spectral line at 172 Hz is
the representation of defect on the outer race of the
bearing (Taylor, 1980). 321
13.5 Signal analysis by spectrum. 323
13.6 Information for the AE event. 328
13.7 Prognostic and health-management system. 335
14.1 An illustration of the pattern of the log cumulative
hazard rate. 353
14.2 The pattern of the hazard rate function assuming a
good-as-new condition. 354
14.3 A TTT-plot to find the optimal replacement time
intervals. 360
14.4 TTT-plot when parameter z=-1. 361
14.5 TTT-plot when parameter z=O. 361
14.6 TTT-plot when parameter z=1. 362
14.7 An illustration of the block replacement policy with
minimal repair. 363