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Joint optimization of preventive maintenance and spare parts inventory using genetic algorithms and particle swarm optimization algorithm

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Abstract

The problem of joint optimization of preventive maintenance and spare parts inventory was solved in this paper. The novelty of this study lies with the fact that the developed method could tackle not only the artificial test case but also a real-world industrial problem. Various investigators developed several methods and semi-analytical tools for obtaining optimum solutions for this problem. In this study, non-traditional optimization tools, namely genetic algorithms (GA) and particle swarm optimization (PSO) algorithm were utilized to obtain the joint optimum preventive maintenance and spare parts inventory ordering interval. The optimum values of time interval yielded by both the GA and PSO algorithm were compared and found to be in agreement with the published results for the similar models obtained through semi-numerical methods. It proves the applicability of these non-traditional optimization tools to solve these problems. This investigation ended with the analysis of preventive maintenance data taken from an industry, for an electric overhead traveling crane. The optimum time schedules so suggested by the GA and PSO algorithm were found to be cost effective, in comparison with the current practice being followed by the industry. A sensitivity analysis was also conducted at the end for this industrial problem.

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Abbreviations

\(c_{bo}\) :

Backordering cost per unit time in Rs.

\(c_{h}\) :

Inventory holding cost in Rs. per unit time

\(c_{mr}\) :

Cost of minimum repair of a machine in Rs.

\(c_{o}\) :

Inventory ordering cost per order in Rs.

\(c_{pm}\) :

Cost of preventive repair of a machine in Rs.

\(C_H\) :

Total value of inventory holding cost for one maintenance cycle

\(C_{BO}\) :

Total value of total backordering cost

\(f(t)\) :

Failure probability distribution (density) function

\(F(t)\) :

Cumulative probability distribution function

\(h(t)\) :

Hazard rate function

\(h'(t)\) :

First order differentiation of the hazard rate function

\(H(T)\) :

Total number of failures in time interval (0,T)

\(n_f\) :

Total number of failures in a given time interval

\(Pr\{X\}\) :

Probability of occurrence of an event \(X\)

\(R(t)\) :

Reliability function

\(t\) :

Age of a machine

\(T\) :

Time interval for preventive maintenance as well as for ordering of “maintenance spare parts kits” for the machine

\(TC\) :

Total cost rate

\(TC_{I}\) :

Total cost towards inventory

\(TC_{M}\) :

Total cost towards maintenance

\(V_{i}\) :

Velocity vector of a particle in a PSO algorithm

\(X_{i}\) :

Position vector of a particle in a PSO algorithm

\(\alpha\) :

Shape parameter of two-parameters Weibull distribution of type \(\beta t ^ {\alpha -1}\)

\(\beta\) :

Scale parameter of two-parameters Weibull distribution of type \(\beta t ^ {\alpha -1}\)

EOQ:

Economic order quantity

GA:

Genetic algorithms

PSO:

Particle swarm optimization

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology, Kharagpur, Kharagpur, 721302, West Bengal, India

    Nishith Kumar Samal & Dilip Kumar Pratihar

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  1. Nishith Kumar Samal
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  2. Dilip Kumar Pratihar
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Correspondence to Dilip Kumar Pratihar.

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Samal, N.K., Pratihar, D.K. Joint optimization of preventive maintenance and spare parts inventory using genetic algorithms and particle swarm optimization algorithm. Int J Syst Assur Eng Manag 6, 248–258 (2015). https://doi.org/10.1007/s13198-015-0349-3

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