Integrated-optimization of production, preventive maintenance and spare parts inventory of continuous operating series systems

Abstract

The abstract should summarize the contents of the paper in short terms, i.e. 150-This paper introduces an integrated-optimization model of production, preventive maintenance (PM) and spare parts inventory in order to maximize the systems’ availability and minimize the both maintenance and inventory related costs while applying on the continuous operating multi-components series systems of a 210 MW coal-fired thermal power plant in eastern region of India. The PM considers the repairs and mechanical services such as cleaning, checking, adjusting etc. which restore the system in between the ‘as bad as old’ (ABAO) and ‘as good as new’ (AGAN) condition. The multi-objective functions i.e. availability and cost of maintenance and spare parts inventory under spare parts constraint have solved using Generalized Reduced Gradient (GRG) search method under the software LINGO 14. After performing several such preventive maintenances, say j numbers, when system reliability has reached to a minimum level then overhauling including mechanical services, repairs and bulk replacements of the components based on their condition monitoring have proposed for improving the system reliability into as good as new condition. The case study illustrates that the single-objective optimization model considering the cost function alone may not provide a cost-effective preventive maintenance interval, rather, considerations of both the availability and cost as objective functions under spare parts constraint may be a cost-effective approach.