A condition-based opportunistic maintenance policy integrated with energy efficiency for two-component parallel systems

Journal of Industrial Engineering and Management JIEM, 2018 – 11(4): 749-768 – Online ISSN: 2013-0953 – Print ISSN: 2013-8423 https://doi.org/10.3926/jiem.2649 A Condition-Based Opportunistic Maintenance Policy Integrated with Energy Efficiency for Two-Component Parallel Systems Aiping Jiang , Yuanyuan Wang , Yide Cheng Sydney Institute of Language and Commerce, Shanghai University (China) , , Received: May 2018 Accepted: September 2018 Abstract: Purpose: This paper deals with the problem of traditional maintenance model ignoring energy consumption in two-component parallel systems. Thus, the aim of the article is to propose a new maintenance model with ecological consciousness for two-component parallel systems, which can improve the energy utilization and achieve sustainable development. The objective is to obtain the optimal maintenance policy by minimizing total cost. Design/methodology/approach: This paper integrates energy efficiency into condition-based maintenance (CBM) decision-making for two-component parallel systems. Based on energy efficiency, the paper considers the economic dependence between the two components to take opportunistic maintenance. Specifically, the objective function consists of traditional maintenance cost and energy cost incurred by energy consumption of components. In order to assess the performance of the proposed new maintenance policy, the paper uses Monte-Carlo method to evaluate the total cost and find the optimal maintenance policy. Findings: Simulation results indicate that the new maintenance policy is superior to the classical condition-based opportunistic maintenance policy in terms of total costs. Originality/value: For two-component parallel systems, previous researches usually simply establish a condition-based opportunistic maintenance model based on real deterioration data, but ignore energy consumption, energy efficiency (EE) and their contributions of sustainable development. This paper creatively takes energy efficiency into condition-based maintenance (CBM) decision-making process, and proposes a new condition-based opportunistic maintenance policy by using energy efficiency indicator (EEI). Keywords: energy efficiency, condition-based opportunistic maintenance, two-component parallel systems To cite this article: Jiang, A., Wang Y., & Cheng, Y. (2018). A condition-based opportunistic maintenance policy integrated with energy efficiency for two-component parallel systems. Journal of Industrial Engineering and Management, 11(4), 749-768. https://doi.org/10.3926/jiem.2649 -749- Journal of Industrial Engineering and Management – https://doi.org/10.3926/jiem.2649 1. Introduction For fear of sudden failure, most companies are willing to repair/replace their components before breakdown. Garg, Rani, and Sharma (2013) simultaneously consider mechanical service, repair and replacement in periodic preventive maintenance. However, this maintenance policy only focuses on the fixed preventive maintenance interval, but ignore the real deterioration level of components. Nowadays, condition-based maintenance is used extensively in various industries, and companies always regard this method highly to ensure maintenance before breakdown. Although the corporations give high priority to the periodic preventive maintenance or condition-based maintenance, they ignore the fact that maintenance activities can strengthen or weaken the ecological burden exerted by system. Horenbeek, Kellens, Pintelon, and Duflou (2014) points out that energy, resources and environment all belong to the category of ecology. It came to be a common situation that companies take blind eyes to the machines in bad condition, since they will not maintain the components when they can still work, even if these components are gradually in poor state which will increase energy consumption. For instance, a ship company, when encounters motor boilers, blowers, belt conveyor belt relaxation and induced draft fan adjustment door open and closed out of work, will not conduct instant maintenance for the purpose of saving money, if these devices mentioned above incur small problems but they can still on operation. However, the negative point is that continuous uses without maintenance will seriously affect the key indicators alpha value of the combustion conditions (ie, air excess coefficient). In general, when the value is too large, the fan energy consumption increased sharply. With the enhanced awareness of energy conservation, a new trend concerning about saving energy, protecting the environment, and achieving sustainable development is prevalent in modern society. In actual industrial production, a great amount of energy, such as electricity, etc. needs to be consumed to maintain machines’ normal operation, and if the system cannot work in good condition, there would be much more energy loss in the manufacture process and thus pose a huge burden on the whole ecology. Thus, for most of the enterprises, it should be the long-term strategic focus how they can apply valid maintenance activities to the improvement of system's resource utilization and establishment of a green image. Traditional maintenance mainly focuses on controlling maintenance fee at a low level and keeping the reliability of the system at a high level, but ignores to avoid excessive energy consumption under operation. Therefore, it is imperative to consider the energy consumption of system under operation when developing a maintenance policy. The rest of the paper is structured as follows: In section 2, several related research literatures are reviewed. Section 3 presents degradation model of individual component and introduces the energy efficiency indicator. Section 4 proposes the new condition-based opportunistic maintenance policy integrated with energy efficiency (EE). Section 5 conducts numerical experiments to testify the advantage of new proposed policy by comparing new proposed and classical maintenance policy. Finally, conclusions and future work are stated in Section 6. 2. Literature Review The reliability and maintainability are the critical factors for maintenance activities, because their purpose is to estimate the probability of failure. Therefore, some scholars are interested in studying the reliability and failure function. For example, Garg and Sharma (2012) propose a two-phase approach to get more precise distribution parameters of reliability, failure rate and repair rate. Maintenance plays a significant role in an industrial system to ensure normal operation. However, most industrial systems are rather complicated and they have some subsystems with components. In order to save money, time and manpower, managers are suggested using three indicators simultaneously, including reliability, availability and maintainability, to find the critical components that affects the performance of the entire system mostly (Garg, 2014a,b). With the development of the sensor technology, cond (...truncated)