Technical System Maintenance: Delay-Time-Based Modelling

361 Pages·2019·9.741 MB·English

by  Sylwia Werbińska-Wojciechowska

Springer Series in Reliability Engineering
Sylwia Werbińska-Wojciechowska
Technical
System
Maintenance
Delay-Time-Based Modelling
Springer Series in Reliability Engineering
Series editor
Hoang Pham, Piscataway, USA
More information about this series at http://www.springer.com/series/6917
ń
Sylwia Werbi ska-Wojciechowska
Technical System
Maintenance
Delay-Time-Based Modelling
123
Sylwia Werbińska-Wojciechowska
Wroclaw University of Science
andTechnology
Wroclaw,Poland
ISSN 1614-7839 ISSN 2196-999X (electronic)
SpringerSeries inReliability Engineering
ISBN978-3-030-10787-1 ISBN978-3-030-10788-8 (eBook)
https://doi.org/10.1007/978-3-030-10788-8
LibraryofCongressControlNumber:2018965885
©SpringerNatureSwitzerlandAG2019
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Preface
The importance of maintenance has increasing for recent past decades. Till now,
many valuable contributions to maintenance modelling concepts have been made.
Thus, this book gives a detailed introduction to maintenance policies and provides
the current status and further studies of these fields, emphasizing mathematical
formulation and optimization techniques.
The emphasis ofthe book is mainly on a delay-time (DT) modelling technique,
whichhasbeenemployedbymanyauthorsinthefieldofmaintenanceengineering
in the modelling of inspection intervals. The author focuses on the delay-time
modelling for multi-unit technical systems performing in various reliability struc-
tures,discussingtheoptimummaintenancepoliciesbothanalyticallyandpractically.
There are considered typical reliability system architectures: single-unit systems,
series systems, parallel systems, and n -out-of-n systems. The new developed
k
maintenance models extend the approach used so far and allow analysing the
long-term operation time period and perfect inspection actions performance.
This book is intended to summarize the research results studied mainly by the
author in the past seven years. Furthermore, it is based on the author's experience
gainedduringtheperformanceofresearchprojectsinthefieldsoflogisticsupport,
maintenance, and delay-time modelling.
Thisbookiscomposedofsevenchapters.Chapter1isdevotedtoanintroduction
to the maintenance theory. The main definitions connected with the analysed
research area are discussed. Moreover, the classification of the main maintenance
problemsbeinginvestigatedintherecentliteratureisgiven.Theaimofthisbookand
its scope isalso presented.
Chapter 2 summarizes the results of preventive maintenance, one of the most
commonlyusedmaintenancestrategy.Thereviewedliteratureisclassifiedintotwo
main groups of models for one-unit and multi-unit systems. The optimum policies
are discussed, and their several modified and extended models are presented.
Chapter 3 deals with inspection maintenance modelling issues. The discussed
modelsforsingle-unitsystemsincludesuchmodellingissueslikeshockoccurrence,
information uncertainty, sequential inspection, or imperfect inspection perfor-
mance. The models for multi-unit systems regard to the two types of technical
v
vi Preface
objects—protective devices (or standby units) and operational units. The main
extensions of the developed models are discussed and summarized.
Chapter 4 presents the literature review on the delay-time modelling for single-
andmulti-unit(complex)systems.Themaintenancemodelsforsingle-unitsystems
assume two-stage or three-stage failure processes. In the case of complex systems,
the discussed problems regard to e.g. models’ parameters estimation issues, case
studies analysis, or hybrid modelling approach implementation.
In Chap. 5, the author introduces the delay-time based maintenance models for
multi-unit technical systems in various reliability structures (series, parallel, n -
k
out-of-n types) for the two cases of perfect and imperfect inspection performance.
First, the necessity of the DT modelling for multi-unit systems performing in
various reliability structures is discussed. The research gap is underlined and
structureoftheChapterispresented.Moreover,preliminarysimulationDTmodels
are characterized. They focus on availability and maintenance costs of technical
systems in series and non-series structures with perfect and imperfect inspection.
In Sect. 5.2 the new analytical delay-time maintenance models are developed.
First, the main assumptions for the DT models are defined. This gives the possi-
bilitytoobtainthemainreliabilityfunctionsforthemodelledsystemperformingin
various reliability structures. Later, the expected maintenance cost model is
introduced.
Section 5.3 provides the reader with extended delay-time maintenance models
forsystemsperforminginvariousreliabilitystructures.Themaintenancemodelsfor
series and parallel systems are discussed. In the next Subchapters there are also
discussed and analysed the convergence of the given analytical model with the
simulationoneandpossibilities oftheobtained simple DTmodels for determining
the best inspection time interval.
In Chap. 6 some important properties of the models are discussed with inves-
tigationofaproblemofmodels’parametersestimationprocessanditsuncertainty.
Later, there is given a simple methodology of applying delay-time analysis to a
maintenance and inspection department. The defined algorithm is aimed at esti-
mation of optimal inspection interval basing on the DT models developed in
Chap. 5 and results obtained from the modelling parameters estimation analysis.
Finally, two case studies are proposed to investigate the optimal inspection
interval for two-unit systems performing in series and parallel structures. The
models used to analyse the given systems are based on the results of Chap. 5 and
Sect.6.2.Thefirstexampleregardstoengineequipmentmaintenance(v-ribbedbelt
with belt tensioner), thesecond examplepresentsthemaintenanceof left and right
steering dumpers that are used in wheel loaders. In order to obtain the optimal
inspection interval the author focuses on cost optimisation. The third example
regards to the problem of maintenance policy selection based on the available
operational and maintenance data from a company.
In the last chapter, the main conclusions and directions for further research are
defined and discussed. The author also summarizes the main contribution of this
book. Moreover, the appropriate References section including works cited in the
book is given.
Preface vii
In the Attachment, there are presented exemplary simulation programs for the
developed delay-time based maintenance models (for perfect and imperfect
inspectioncases).Moreover,theadditionalresultsforconductedanalysispresented
in Sect. 6.2 are given. The Attachment 4 provides the reader with the list of the
main maintenance standards.
ThearticlesreferredtointhisstudywerefoundusingGoogleScholarasasearch
engine and ScienceDirect, JStor, SpringerLink, SAGEJournals, De Gruyter,
EBSCO, and Taylor & Francis as online databases. The author primarily searched
the relevant literature based on keywords, abstracts and titles. Moreover, she also
searched within the articles for relevant references. The following main terms
and/or a combination of them were used for searching the literature: maintenance,
maintenance optimization, maintenance management, preventive maintenance,
delay time maintenance, inspection maintenance. The literature overview was also
supplied with relevant books and proceedings that were available for the author
(e.g.basedonAccessEngineeringe-bookresourcesdatabase,andSpringerLink,or
Taylor & Francis eBooks databases).
Although the author has tried to give a reasonably complete survey, the reader
maynotethatsomepapersaremissing(e.g.untranslatedAsiaticpapers).Thus,the
author apologizes to both the readers and the researchers if she has omitted any
relevant papers in the analysed research area.
This book is a valuable resource for understanding the latest developments in
maintenance,inspectionanddelay-timebasedmaintenancemodellingissues.Thus,
it will be useful to many people including maintenance engineers, reliability spe-
cialists, graduate and senior undergraduate students, and researchers, who are
interested in reliability and maintenance. The sources of the material presented are
giveninthereferenceChapterattheendofthebookforthebenefitofthereaderif
he/shewishestodelvedeeperintoparticulartopics.IbelievethatalltheChaptersof
this book will introduce the readers to the major up-to-date theory and practice in
maintenance modelling issues especially in the field of delay-time modelling.
The author wouldlike toexpresshersincere appreciationtoall thecontributors
to this book. I am also indebted to Professor Tomasz Nowakowski, Wroclaw
University of Technology, Poland, and PhD Eng. Anna Jodejko-Pietruczuk,
Wroclaw University of Technology, Poland for their valuable assistance and
comments. I also thank my family for their patience and support.
Wroclaw, Poland Sylwia Werbińska-Wojciechowska
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Preventive Maintenance Models for Technical Systems . . . . . . . . . . 21
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Preventive Maintenance for a Single-Unit System. . . . . . . . . . . . . 25
2.2.1 Age-Replacement Policies . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.2 Block-Replacement Policies . . . . . . . . . . . . . . . . . . . . . . . 32
2.2.3 Other Maintenance Policies for a Single-Unit System . . . . 37
2.3 Preventive Maintenance for a Multi-unit System. . . . . . . . . . . . . . 50
2.3.1 Age-Replacement Policies . . . . . . . . . . . . . . . . . . . . . . . . 50
2.3.2 Block-Replacement Policies . . . . . . . . . . . . . . . . . . . . . . . 54
2.3.3 Group Maintenance Policies. . . . . . . . . . . . . . . . . . . . . . . 58
2.3.4 Opportunity-Based Maintenance Policies. . . . . . . . . . . . . . 69
2.3.5 Cannibalization Maintenance Policies . . . . . . . . . . . . . . . . 81
2.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3 Inspection Models for Technical Systems . . . . . . . . . . . . . . . . . . . . . 101
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.2 Inspection Models for a Single-Unit System. . . . . . . . . . . . . . . . . 107
3.3 Inspection Models for a Multi-unit System. . . . . . . . . . . . . . . . . . 130
3.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4 Delay-Time Maintenance Models for Technical Systems. . . . . . . . . . 161
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.2 Basic Delay-Time Models for a Single-Unit System. . . . . . . . . . . 166
4.3 Basic Delay-Time for a Complex System. . . . . . . . . . . . . . . . . . . 180
4.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
ix
x Contents
5 Delay-Time Models for Multi-unit Technical Systems
Working in Various Reliability Structures . . . . . . . . . . . . . . . . . . . . 207
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
5.2 Simple Delay-Time Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.2.1 Reliability Models for a System with Delay Time
Working in Various Reliability Structures. . . . . . . . . . . . . 227
5.2.2 Expected Maintenance Costs Model . . . . . . . . . . . . . . . . . 229
5.3 Extended Delay-Time Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
5.3.1 DT Maintenance Model for a Two-Element System
Performing in Series Reliability Structure . . . . . . . . . . . . . 230
5.3.2 DT Maintenance Model for a Two-Element System
Performing in Parallel Reliability Structure . . . . . . . . . . . . 245
5.4 Convergence of a Chosen Analytical Model with Developed
Simulation Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
5.5 TheUseofaChosenDTModeltoDeterminetheBestInspection
Time Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
5.6 Concluding Remarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
6 Delay Time Models Implementation Issues. . . . . . . . . . . . . . . . . . . . 263
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
6.2 Models’ Parameters Estimation Process . . . . . . . . . . . . . . . . . . . . 266
6.3 Maintenance Decision-Making Process—Simple Decision Rules
and Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
6.4 Case Studies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
6.4.1 Case Study for a Two-Component Series System . . . . . . . 288
6.4.2 Case Study for a Two-Component Parallel System . . . . . . 292
6.4.3 Case Study for a Maintenance Policy Decision Process
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
6.5 Concluding Remarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
7 Conclusions and Further Research . . . . . . . . . . . . . . . . . . . . . . . . . . 307
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
Appendix A: An Exemplary Simulation Program (Source Code)
foraDTModelforMulti-unitSystemsinannk-Out-of-n
Structure (Perfect Inspection Case).. .... .... ..... .... 323
Appendix B: An Exemplary Simulation Program (Source Code)
foraDTModelforMulti-unitSystemsinann -Out-of-n
k
Structure (Imperfect Inspection Case).... .... ..... .... 329
AppendixC:ChosenResultsforOptimalPeriodT fromDelayTime
in
Dispersion Tests ..... .... .... .... .... .... ..... .... 335
Appendix D: Chosen Standards Related to Maintenance.... ..... .... 341