A Multi-attribute Approach for Simultaneous Determination of Preventive Replacement Times and Order Quantity of Spare Parts

Document Type: Research Paper

Authors

1 Department of Industrial Engineering, Isfahan University of Technology, Isfahan, Iran

2 Department of Industrial Engineering, Faculty of Engineering, University of Kashan, Kashan, Iran

Abstract

One of the most important activities in preventive maintenance is replacement of spare parts prior to failure. The aim of this paper is to propose an approach which determines jointly the preventive replacement interval and the spare parts inventory by considering different criteria and interacting with decision makers. In this approach, preventive replacement intervals, determined by experts of production and maintenance, are ranked by analytical hierarchy process (AHP). Criteria such as cost per unit of time, availability, remaining lifetime, and reliability are used. Then, a mixed integer nonlinear multi-objective model presented that it simultaneously specifies the period of preventive replacement and the required number of spare parts. This model considers the mentioned criteria and the inventory control costs of spare parts as different objective functions. Since, the solution of the problem depends on the decision maker’s strategy, it need interact with the decision-makers and consequently the proposed model could be solved using goal programming approach. The applicability of the proposed approach is illustrated by two numerical examples. The effect of key parameters on the optimal decisions is investigated for two examples.

Keywords

Main Subjects


Alsyouf I. (2007). The role of maintenance in improving companies, productivity and profitability, International Journal of Production Economics, Vol. 105, pp. 70-78.

Arunraj N.S. and Maiti J. (2010). Risk-based maintenance policy selection using AHP and goal programming, Safety Science, Vol.48, pp.238-247.

Au-Yong Ch. P., Ali A.Sh. and Ahmad F. (2016). Enhancing building maintenance cost performance with proper management of spare parts, Journal of Quality in Maintenance Engineering, Vol. 22(1), pp. 51-61.

Ba K., Dellagi S., Rezg N. and Erray W. (2016). Joint optimization of preventive maintenance and spare parts inventory for an optimal production plan with consideration of CO 2 emission, Reliability Engineering & System Safety, Vol. 149, pp. 172-186.

Barlow R. E. and Proschan F. (1965). Mathematical theory of reliability, Wiley, New York.

Bashiri M., Badri H. and Hejazi T.H. (2011), Selecting optimum maintenance strategy by fuzzy interactive linear assignment method, Applied Mathematical Modelling, Vol. 35, pp. 152–164.

Basten R. and Van Houtum, G. (2014). System-oriented inventory models for spare parts, Surveys in operations research and management science, Vol. 19(1), pp. 34-55.

Boland P.J. and Proschan F. (1982). Periodic replacement with increasing minimal repair costs at failure, Operation research, Vol.30, pp.1183-1189.

Cavalcante C.A.V. and de Almeida A.T. (2007). A multi-criteria decision-adding model using PROMETHEE III for preventive maintenance planning under uncertain conditions, Journal of Quality in maintenance engineering, Vol. 13(4), pp.385-397.

Cavalcante C.A.V. (2008). A preventive decision model based on multicriteria method PROMETHEE II integrated with Bayesian approach, IMA Journal of management mathematics, Vol.21(4), pp.333-348.

Chareonsuk C., Nagarura N. and Tabucanona M.T. (1997). A multicriteria approach to the selection of preventive maintenance intervals, International Journal of Production Economics, Vol.49, pp.55-46.

Cheng Y.H. and Tsao H.L. (2010). Rolling stock maintenance strategy selection spares parts’ estimation, and replacements’ interval calculation, International Journal of Production Economics, Vol. 128, pp. 404-412.

Chien Y.H. (2009). A number dependent replacement policy for a system with continuous preventive maintenance and random lead times, Applied mathematical modeling, Vol. 33, pp.1708-1718.

Chien Y.H., Chang C. and Sheu S.H. (2010). The optimal age-replacement model with the age-dependent type of failure and random lead time based on cumulative repair-cost limit policy, Journal of Annals of Operation Research, Vol. 181(1), pp.723-744.

De Almeida A.T., Ferreira R.J.P. and Cavalcante C.A.V. (2015). A review of the use of multicriteria and multi-objective models in maintenance and reliability, IMA Journal of Management Mathematics, Vol. 26, pp. 249-271.

Dekker R. (1996). Applications of maintenance optimization models: a review and analysis, Reliability engineering and system safety, Vol. 51, pp.229-240.

Fallahnezhad M.S. and Pourgharibshahi M. (2017). Determining an optimal maintenance policy for three state machine replacement problem using dynamic programming, International Journal of Supply and Operations Management, Vol. 4 (2), pp. 180-192.

Gopalaswamy V., Rice J. A. and Miller F. G. (1993). Transit vehicle component maintenance policy via multiple criteria decision-making methods, Journal of the Operational Research Society, Vol.44, pp.37–50.

Hasannia Kolaee M. and Torabi S. A. (2017). Supplier and Carrier Selection and Order Allocation by Considering Disruptions with AHP and Multi-objective Mathematical Programming, International Journal of Supply and Operations Management, Vol. 4(4), pp. 359-369.

Huang R.H., Meng L., Xi L. and Liu C.R. (2008). Modeling and analyzing a joint optimization policy of block-replacement and spare inventory with random-lead time, IEEE Transaction reliability, Vol. 57(1), pp. 113-124.

Ilgin MA, Tunali S. (2007). Joint optimization of spare parts inventory and maintenance policies using genetic algorithms, International journal advanced manufacturing technology, Vol. 34, pp. 594–604.

Jiang R. and Ji P. (2002). Age replacement policy: a multi-attribute value model, Reliability engineering and system safety, Vol.76, pp.311-318.

Jiang Y., Chen M. and Zhou D. (2015). Joint optimization of preventive maintenance and inventory policies for multi-unit systems subject to deteriorating spare part inventory, Journal of Manufacturing Systems, Vol. 35, pp. 191–205.

Keizer M. C. A. O., Teunter R. H. and Veldman J. (2017). Joint condition-based maintenance and inventory optimization for systems with multiple components, European Journal of Operational Research, Vol. 257(1), 209-222.

Makabe H. and Marimura H. (1965). Some considerations on preventive maintenance policies with numerical analysis, The Operations Research Society of Japan, Vol. 7(4), pp. 154-171.

Nakagawa T. (2005). Maintenance theory of reliability, Springer, USA.

Nosoohi I. and Hejazi S.R. (2011). A multi-objective approach to the simultaneous determination of spare part numbers and preventive replacement times, Applied Mathematical Modelling, Vol.35(3), pp.1157-1166.

Najari F., Sobhanallahi M.A. and Mohammadi M. (2018). Improving maintenance strategy by physical asset management considering the use of MFOP instead of MTBF in petrochemical, International Journal of Supply and Operations Management, Vol. 5(4), pp. 319-337.

Panagiotidou S. (2014). Joint optimization of spare parts ordering and maintenance policies for multiple identical items subject to silent failures, European Journal of Operational Research, Vol. 235, pp. 300–314.

Quan G., Greenwood G.W., Liu D. and Hu S. (2007). Searching for multiobjective preventive maintenance schedules: combining preferences with evolutionary algorithms, European Journal of Operational Research, Vol.177, pp.1969–1984.

Romero C. (2001). Extended lexicographic goal programming: a unifying approach, Omega, Vol. 29(1), pp. 63-71.

Saaty T.L. (1980). The Analytic Hierarchy Process, McGraw-Hill International, New York, USA.

Sarker R. and Haque A. (2000). Optimization of maintenance and spare provisioning policy using simulation, Applied Mathematical Modelling, Vol. 24, pp. 751-760.

Sharma A. and Yadava G.S. (2011). A literature review and future perspectives on maintenance optimization, Journal of Quality in Maintenance Engineering, Vol. 17, pp. 5-25.

Shi Y., Xiang Y., Jin T., and Li Y. (2016). Joint planning for spare parts inventory and preventive maintenance in a multi-echelon network, International Journal of Inventory Research, Vol. 3(3), pp. 263-281.

Tamiz M, Jones D. and Romero C. (1998). Goal programming for decision making: An overview of the current state-of-the-art. European Journal of Operational Research, Vol. 111, pp. 569-581.

Triantaphyllou E., Ovalerchuk B., Mann L. and Knapp G.M. (1997). Determining the most important criteria in maintenance decision making, Journal of quality maintenance engineering, Vol. 3(1), pp.16-28.

Wang G.J. and Zhang Y.L. (2006). Optimal periodic preventive replacement policy assuming Geometric process repair, IEEE Transactions on Reliability, Vol. 55(1), pp. 118-122.

Wang W. (2011). A joint spare part and maintenance inspection optimization model using the delay time concept, Reliability Engineering and Systems Safety, Vol. 96, pp. 1535-1541.

Yang R. and Kang J. (2017). A joint optimal policy of block preventive replacement and spare part inventory, International Journal system assurance engineering management, Vol. 8(4), pp. 740-746.

Yoo Y.K., Kim K.J. and Seo J. (2001). Optimal joint spare stocking and block replacement policy, International journal advanced manufacturing technology, Vol. 18, pp. 906–909.

Zahedi-Hosseini F., Scarf Ph. and Syntetos A. (2017). Joint optimization of inspection maintenance and spare parts provisioning: a comparative study of inventory policies using simulation and survey data, Reliability Engineering & Systems Safety, Vol 168, pp. 306-316. 

Zahedi-Hosseini F., Scarf Ph. And Syntetos A. (2018). Joint maintenance-inventory optimization of parallel production systems, Journal of Manufacturing Systems, Vol. 48, pp. 73–86.

Zeng S. W. (1997). Discussion on maintenance strategy, policy and corresponding maintenance systems in manufacturing, Reliability Engineering & Systems Safety, Vol. 55, pp. 151-162.