Multi-Level Optimization Policy of Opportunistic Maintenance and Inventory Control of k-out-of-n System

doi:10.16183/j.cnki.jsjtu.2022.030

Abstract

Abstract:

For the maintenance outsourcing requirements of complex systems in service-oriented manufacturing, a multi-level optimization policy of opportunistic maintenance and inventory control (OMICP) is proposed by considering the challenges of redundant machine interference, high shutdown penalty, and spare parts inventory limit of k-out-of-n: G system. At the machine layer, the degeneration model of each machine is built. Then, preventive maintenance cycles of each machine are outputted in sequence by minimizing the maintenance cost rate. At the system level, these maintenance time points are taken as opportunities. In addition, a dynamic combination opportunistic maintenance policy is established by comprehensively considering inventory level, shutdown quantity, and redundancy interference. At the joint level, based on the opportunistic maintenance decision feedback, the inventory control policy is updated in real time by modeling and analyzing the profit balance of spare parts ordering. Through this multi-level interactive decision-making under outsourcing maintenance, the coupling relationship between complex system maintenance and inventory control is integrated to optimize the total cost of maintenance outsourcing services. The case study has shown that OMICP has the feasibility of complex decision-making and the effectiveness of cost optimization.

Key words: maintenance outsourcing, k-out-of-n: G system, opportunistic maintenance, inventory control, multi-level optimization

CLC Number:

TH17

CAO Lei, AN Xiangxin, XIA Tangbin, ZHENG Meimei, XI Lifeng. Multi-Level Optimization Policy of Opportunistic Maintenance and Inventory Control of k-out-of-n System[J]. Journal of Shanghai Jiao Tong University, 2023, 57(3): 285-296.

Figures/Tables 12

Fig.1

Fig.2

Tab.1

Maintenance and outsourcing parameters of each machine

j	β_j	η_j	ε_j	$T P i j$ /h	$T R i j$ /h	$C P i j$ /美元	$C R i j$ /美元	$V S j$ /美元	$V E j$ /美元	δ_j	$C D i j$ /美元	c_d/美元
1	3.1	7 000	1.035	20	66	6 500	18 000	700 000	630 000	0.11	2 400	3 000
2	2.8	6 800	1.042	25	74	7 000	20 000	760 000	660 000	0.15	2 800	3 000
3	3.1	7 200	1.054	20	58	6 400	18 800	700 000	650 000	0.12	2 200	3 000
4	2.9	7 500	1.041	18	68	6 000	16 800	730 000	650 000	0.16	2 800	3 000
5	2.8	6 600	1.036	15	55	6 800	22 900	750 000	670 000	0.12	2 500	3 000

Tab.1

Tab.2

Tab.3

Opportunistic maintenance decision of 8th system-layer cycle

j	t_ij/h	t₈/h	$T i j *$ /h	T'_ij/h	MPA_j₈/美元	MPR_j₈/美元	MPS_j₈/美元	Ω(j, t₈)
1	14 051	13 662	4 675	4 286	5 923.41	1 168.55	3 724.15	1
2	13 662	13 662	4 471	4 471	—	—	—	1
3	13 860	13 662	4 669	4 471	3 610.42	554.35	3 056.07	1
4	17 429	13 662	4 997	1 230	6 488.41	35 697.68	-29 209.28	0
5	16 304	13 662	3 872	1 230	6 945.97	26 402.82	-19 456.84	0

Tab.3

Tab.4

Optimized maintenance decision of 8th system-layer cycle

j	Ω(j, t₈)	P_j₈/美元	MPS'_j₈/美元	Ω(j, t₈)'	$T 8 P$ /h
1	1	60 000.00	-56 275.85	1	25
2	1	—	—	1	25
3	1	60 000.00	-56 943.93	0	25
4	0	—	—	0	25
5	0	—	—	0	25

Tab.4

Tab.5

Inventory control decision for 4th joint-layer cycle

y_s4/件	IP $R y s 4 F$ /美元	IP $R y s 4 H$ /美元	IP $S y s 4$ /美元
0	0	0	0
1	4 000	510	-4 510
2	4 000	1 020	-5 020
3	4 000	1 530	-5 530

Tab.5

Tab.6

Tab.7

Fig.3

Fig.4

Fig.5

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u	t_u/h	v_s_u/件	Ω(j,t_u)					y_w/件
u	t_u/h	v_s_u/件	j=1	j=2	j=3	j=4	j=5	y_w/件
1	4 230	2	0	0	0	1	PM	4
2	4 604	4	0	PM	1	0	0	0
3	4 779	2	PM	0	0	0	0	6
4	8 425	4	0	0	0	1	PM	0
5	9 166	2	0	PM	1	0	0	0
6	9 356	2	PM	0	0	0	0	6
7	12 414	6	0	0	0	1	PM	0
8	13 662	4	1	PM	0	0	0	0
9	13 860	2	0	0	PM	0	0	0
10	16 304	1	0	0	0	0	PM	1
11	17 429	1	0	0	0	PM	0	3
12	18 093	3	0	PM	1	0	0	0
13	18 310	1	PM	0	0	0	0	1
14	20 143	1	0	0	0	0	PM	1
15	22 375	1	0	0	0	PM	0	6
16	22 460	6	0	PM	0	0	0	0
17	22 632	4	1	0	PM	0	0	—

成本/美元	SMP+(S, s) S=3 s=2	OM		IC		Joint Opt		OMICP
成本/美元	SMP+(S, s) S=3 s=2	OM+(S,s) S=2 s=1	OM+(S,s) S=3 s=2	IPM+IC	SMP+IC	2014 RESS 文献[16]	2021 EJOR 文献[15]	OMICP
C_D	80 365	56 920	51 420	79 130	73 430	78 555	79 421	56 480
C_P	163 500	176 700	172 780	159 540	130 800	163 500	163 500	172 780
C_R	128 865	116 220	90 340	132 740	176 050	116 315	123 591	85 780
C_B	63 000	15 000	12 000	5 400	147 000	35 400	37 350	12 000
C_F	100 000	62 400	60 000	38 400	20 400	96 000	10 280	38 400
C_U	166 500	171 000	169 000	170 000	151 500	149 350	157 800	156 000
C_H	157 501	170 932	236 470	214 069	86 292	80 500	149 125	132 673
C_E	21 000	42 000	22 400	17 500	24 500	41 090	6 860	23 800
维护相关成本	355 365	364 840	326 540	376 810	527 280	393 770	403 862	327 040
库存相关成本	445 001	446 332	487 870	439 969	282 692	366 940	324 065	350 873
总成本	880 731	811 172	814 410	816 779	809 972	760 710	727 927	677 913