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ADVANCES
IN SYSTEM
RELIABILITY
ENGINEERING
ADVANCES
IN SYSTEM
RELIABILITY
ENGINEERING
Edited by
MANGEY RAM
J. PAULO DAVIM
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A catalogue record for this book is available from the British Library
ISBN: 978-0-12-815906-4
Mohini Agrawal
School of Business, Galgotias University, Greater Noida, India
Adarsh Anand
Department of Operational Research, University of Delhi, New Delhi, India
Alessandro Barbiero
Department of Economics, Management and Quantitative Methods, Università degli Studi
di Milano, Milan, Italy
Navneet Bhatt
Department of Operational Research, University of Delhi, New Delhi, India
F. De Caro
Department of Engineering, University of Sannio, Benevento, Italy
Lirong Cui
School of Management & Economics, Beijing Institute of Technology, Beijing, China
Ant^
onio Carlos Lopes da Costa
Centro de Desenvolvimento da Tecnologia Nuclear—CDTN, Belo Horizonte, Brazil
Vanderley de Vasconcelos
Centro de Desenvolvimento da Tecnologia Nuclear—CDTN, Belo Horizonte, Brazil
Chen Fang
School of Management & Economics, Beijing Institute of Technology, Beijing, China
Soufiane Gasmi
Optimization, Modeling and Decision Support (OMAD), University of Tunis—Tunis
National Higher School of Engineering, Tunis, Tunisia
Miroslav Kvassay
Department of Informatics, University of Zilina, Zilina, Slovakia
Dongjin Lee
School of Computing, Informatics, and Decision Systems Engineering, Arizona State
University, Tempe, AZ, United States of America
Preeti Malik
Department of Computer Science and Engineering, Graphic Era Deemed to be University,
Dehradun, India
Monika Manglik
Department of Mathematics, University of Petroleum & Energy Studies, Dehradun, India
Lata Nautiyal
Department of Computer Science and Engineering, Graphic Era Deemed to be University,
Dehradun, India
ix
x Contributors
Rong Pan
School of Computing, Informatics, and Decision Systems Engineering, Arizona State
University, Tempe, AZ, United States of America
Brian A. Polin
Jerusalem College of Technology, Jerusalem, Israel
Ludmila Pustylnik
Department of Mechanical Engineering, Afeka Tel-Aviv Academic College of Engineering,
Tel Aviv, Israel
Jan Rabcan
Department of Informatics, University of Zilina, Zilina, Slovakia
Mangey Ram
Department of Mathematics, Computer Science & Engineering, Graphic Era University,
Dehradun, India
Amanda Laureano Raso
Centro de Desenvolvimento da Tecnologia Nuclear—CDTN, Belo Horizonte, Brazil
Alexander Rotshtein
Department of Industrial Engineering, Jerusalem College of Technology, Jerusalem, Israel
Patrik Rusnak
Department of Informatics, University of Zilina, Zilina, Slovakia
Luis Mejia Sanchez
Cummins Inc., Columbus, IN, United States of America
Wellington Antonio Soares
Centro de Desenvolvimento da Tecnologia Nuclear—CDTN, Belo Horizonte, Brazil
A. Vaccaro
Department of Engineering, University of Sannio, Benevento, Italy
D. Villacci
Department of Engineering, University of Sannio, Benevento, Italy
Sylwia Werbi nska-Wojciechowska
Department of Operation and Maintenance of Logistic Systems, Transportation Systems and
Hydraulic Systems, Wroclaw University of Science and Technology, Wroclaw, Poland
Petek Yontay
Intel, Inc., Chandler, AZ, United States of America
EDITORS BIOGRAPHY
xi
xii Editors Biography
xiii
xiv Preface
to help them in their reliability courses. This book is meant for those who take
reliability and safety as a subject of study.
The editors acknowledge Elsevier for this opportunity and for their
professional support. Finally, we would like to thank all the chapter authors
for their availability for this work.
Mangey Ram
Dehradun, India
J. Paulo Davim
Aveiro, Portugal
ACKNOWLEDGMENTS
The editors acknowledge Elsevier and the editorial team for their adequate
and professional support during the preparation of this book. Also, we would
like to acknowledge all of the chapter authors and reviewers for their avail-
ability for work on this book project.
Mangey Ram
Graphic Era Deemed to University, Dehradun, India
J. Paulo Davim
University of Aveiro, Aveiro, Portugal
xv
CHAPTER 1
Delay-Time-Based Maintenance
Modeling for Technical Systems—
Theory and Practice
ska-Wojciechowska
Sylwia Werbin
Department of Operation and Maintenance of Logistic Systems, Transportation Systems and Hydraulic
Systems, Wroclaw University of Science and Technology, Wroclaw, Poland
Abstract
This chapter will be a valuable resource for understanding the latest developments in
maintenance modeling issues in the field of delay-time approach implementation. This
chapter presents the literature review on delay-time modeling for single- and multiunit
systems. The maintenance models for single-unit systems assume two-stage or three-
stage failure processes. In the case of complex systems, the discussed problems are with
regard to models’ parameters, estimation issues, case studies analysis, or hybrid model-
ing approach implementation. The maintenance models for multiunit systems examine
the known models for nonseries systems. A case study for maintenance modeling for
multiunit systems based on a delay-time approach is provided. The directions for further
research work are defined.
Abbreviations
AIC Akaike information criterion
BI Block Inspection
CM corrective maintenance
DT delay time
DTA delay-time approach
DTM delay-time models
ELECTRE elimination and choice expressing the reality
HPP homogeneous Poisson process
MAUT multiattribute utility theory
MC Monte Carlo
MLE maximum likelihood estimation
MRT mean repair time
MTBF mean time between failures
NHPP nonhomogeneous Poisson process
PAR proportional age reduction
PM preventive maintenance
PROMETHEE preference ranking organization method for enrichment evaluations
Important Notations
c(Tin) expected cost over each inspection cycle
c(Tini) expected cost over ith inspection cycle
C(Tin) total costs resulting from chosen maintenance policy
ccs clean-up cost connected with cleaning up any spillage that may result in a
failure
cin cost of inspection action performance
cp cost of preventive replacement of a unit
cr cost of failed unit replacement
din time of single inspection action performance
dp the time of preventive replacement of a system
dr time of corrective replacement of a system (after a failure)
E[x] expected value of random variable x
Ed(Tin) expected downtime in an inspection cycle of length Tin
F(t) probability distribution function of system/unit lifetime; F(t)¼1F(t)
Fh(h) probability distribution function of system delay time
fh(h) probability density function of system delay time
Fhi(h) probability distribution function of ith element delay time
fhi(h) probability density function of ith element delay time
Gh(t) probability distribution function of the initial time u, which elapses from
the beginning of operation by “as good as new” elements of a system until
the moment of first symptoms of failure occurrence
gh(t) probability density function of the initial time u, which elapses from the
beginning of operation by “as good as new” elements of a system until
the moment of first symptoms of failure occurrence
Ghi(t) probability distribution function of initial time u of ith element in a system
ghi(t) probability density function of initial time u of ith element in a system
h delay time of a defect, denoting the period between the moment of appear-
ance of the first symptoms of potential failure and the moment of an
object’s failure occurrence
ku constant rate for fault’s arrival in a technical system for any
inspection period
Mcs measure of possible impact of a failure of a piece of equipment on an
environment
Menv(Tin) environmental model of a technical object
m number of failures until element replacement
n number of elements in a system
nk minimum number of operating components to make a system function
(performance in nk-out-of-n reliability structure)
Nrin(ti–1in, tiin) expected number of failures over inspection interval (ti–1in, tiin)
pcs probability of a failure resulting in a spillage requiring clean up
pin probability of imperfect inspection occurrence
PuF(Tin) probability of a fault arising as a breakdown in a system
pw probability that, during system inspection, performance symptoms of
forthcoming failures (if they occur in a system) are identified
R(t) reliability function of a system
Delay-Time-Based Maintenance Modeling for Technical Systems—Theory and Practice 3
1 INTRODUCTION
Many real-life systems may display some symptoms of forthcoming failure.
One example may be a production process, which may start producing
defective items after some random amount of time. If the situation is not
corrected, product quality gradually deteriorates to a level where it is self-
evident to an operator that the system has failed. By inspecting the product
quality at some intervals, the operator may be able to reduce the cost
incurred with the system lifetime [1]. These types of components may ben-
efit from an inspection policy whereby a component is inspected for a defect
and consequently replaced at inspection to prevent failure [2]. Recent
reviews on inspection maintenance modeling issues are presented in the lit-
erature [3–9].
The basic inspection models are extended by using a technique called
delay-time analysis (DTA), which was developed for modeling the conse-
quences of an inspection policy for any system [10]. This approach was first
described and investigated by Christer et al. [10–16].
This maintenance concept is based on the assumption that before a sys-
tem breaks down, there will be some signs of its reduced performance. The
time between the first identification of abnormalities (called initial point)
4 Advances in System Reliability Engineering
0 tu tf t
and the actual failure time (called failure point) is called a delay time and
determines the best opportunity to carry out maintenance or an inspection
(Fig. 1). As a result, the delay-time concept defines a two-stage process for
three-stated systems (being either in upstate, partially upstate, or in down-
state). For more information, the author recommends reading Wang
et al. [17].
The inspection schemes in delay-time models may be periodic or based
on condition-based maintenance implementation [18]. In this chapter, the
author focuses on periodic inspection maintenance modeling issues. More
information about condition-based delay-time models may be found in
the literature [19–25].
The interest in DT modeling issues has increased significantly in recent
years. Literature reviews, in which delay-time models are investigated along
with other preventive maintenance models, are given in several studies
[26–32]. The states of art works, dedicated to DT modeling, were mostly
developed in the 1990s. One of the first literature reviews was given by
Christer et al. [19], where the authors discussed a basic DT model for a
single-unit case taking into account model parameters estimation problems.
Later, the state of art was updated in Christer et al. [33]. In this work, math-
ematical methods for updating delay-time models of industrial inspection
practice are proposed. They presented a linear delay-time update method
and model parameter variation. Moreover, the authors also provide a com-
bination of these methods in the maintenance area and defines the criteria for
choosing an updating method.
Christer later presented a basic delay-time model [34] and discussed the
main development directions, including perfect/nonperfect inspection
Delay-Time-Based Maintenance Modeling for Technical Systems—Theory and Practice 5
cases. There have been simple DT models investigated for a repairable com-
ponent and for a complex plant. Moreover, the authors focused on the prob-
lems of a parameter estimation process and DT models’ implementation
possibilities. The work ends with a discussion of further developments in
delay-time modeling. The presented state of art was further extended by
Christer [35]. In this work, the author focuses on investigation of industrial
maintenance problems and presents basic maintenance models for a repair-
able component and a complex plant. The main extensions of the basic
models include, for example, nonperfect inspection case and nonsteady-state
conditions.
One of works that provides recent advances in delay-time-based main-
tenance modeling is given by Wang [36]. In this work, the author focuses on
the main development directions in delay-time-based models. As a result, he
investigates the delay-time models for optimized inspection intervals (distin-
guishing, for example, imperfect inspection and maintenance issues or mul-
tiple inspection intervals problem) and DT modeling application areas
(including e.g., the problem of spare part inventory and maintenance
modeling or maintenance outsourcing issues). The author also defines the
main directions for further research in the analyzed maintenance area.
For more information, the author recommends further reading of the
literature [2, 6, 37, 38]. Some recent developments in this area are also avail-
able for further reading [17, 21, 39].
Following these considerations, in Fig. 2, the main classification of exist-
ing delay-time models is presented. The proposed classification divides the
known models into two main groups of inspection strategies: single- and
multiunit systems.
To sum up, the author summarizes and reviews the existing literature on
periodic delay-time maintenance modeling and clusters the existing works
into several fields, mostly based on the classification on single- and multiunit
models.
Models for system Models for system with Models for complex
Models for multiunit
with two-stage three-stage failure system
system in nonseries
failure process process
reliability structure
The articles referred to in this study were found using Google Scholar as a
search engine and ScienceDirect, JStor, SpringerLink, SAGEJournals, and
Taylor & Francis as online databases. The author primarily searched the rel-
evant literature based on keywords, abstracts, and titles. The following main
terms and/or a combination of them were used for searching the literature:
delay time maintenance or inspection maintenance. As a result, 130 papers from
1982 to 2018 are reviewed in this study.
The applicability of the given maintenance approach is presented in a
case study. The case study is developed based on historical data of mainte-
nance and operation processes of four production plants (injection molding
machines) operated by an international company located in Poland.
These production plants have defined inspection policies based on ser-
vice regulations defined by a producer. However, a company finds that some
developments in this area may be useful to make further decisions.
Following this, this chapter is organized as follows. Sections 2 and 3
examine various types of delay-time modeling approaches for single- and
multiunit systems, which are the most widely known in the literature. In
Section 4, a case study is proposed to investigate the optimal inspection
interval for a four-unit system performing in a series reliability structure.
Section 5 concludes the chapter and highlights future research in DT
modeling.
Systems with a
multiple
failure mode
Fig. 3 Classification scheme of delay-time models for systems with a two-stage failure
process.
ðiÞ
RTin ðtÞ ¼ rTin ðtÞ, where ði 1ÞTin t < iTin (1)
ð∞ ðt )
+ gh ðuÞdu + gh ðuÞM ðt uÞdu ,
u¼t u¼ði1ÞTin
a component with a minor defect and a major defect. It is assumed that the
minor defect is fixed by minor perfect inspections and repairs, whereas the
major defect is dealt with by major imperfect inspections and repairs.
The major defects, if they occur, may not be identified by minor inspec-
tions and repairs. They have to be detected and rectified by major inspec-
tions and repairs, otherwise they can lead to a breakdown of the process.
The model also takes into account the possible relationship between the
two defined defects due to the possible influence of major defects on the
minor defects occurring in the system. The authors aimed at finding
the optimal values for both types of inspection intervals by minimizing
the long-run expected cost per unit time.
The case of imperfect maintenance model for single components with
multiple failure modes was later analyzed by Li et al. [44]. The authors in
their work describe an accumulative age concept and imperfect inspection
maintenance due to insufficient allocation of maintenance resources. The
model is based on the optimization of the average cost per unit time over
an infinite period and average reliability function.