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Adaptive maintenance window-based opportunistic maintenance optimization considering operational reliability and cost

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  • Lu, Yaohui
  • Wang, Shaoping
  • Zhang, Chao
  • Chen, Rentong
  • Dui, Hongyan
  • Mu, Rui

Abstract

Opportunistic maintenance (OM) reduces maintenance costs by combining the maintenance of multiple components. It has recently been widely used in complex systems. However, few studies have considered that advance maintenance results in the insufficient utilization of reliability. Besides, the applicable conditions for advance and postpone maintenance are ignored in existing literature. In this paper, the economic benefits and failure risk of advance and postpone maintenance are evaluated to fully utilize component's reliability. In addition, all maintenance types (preventive maintenance, corrective maintenance, and replacement) and programs (advance and postpone maintenance) for critical components and non-critical components are discussed based on the degree of overlap of the components’ maintenance windows. Then, an operational reliability (OR) model based on system availability is established to reflect the operating state of the system under damage and maintenance. In order to maximize OR and minimize maintenance costs, a multi-objective optimization model for an OM strategy based on adaptive maintenance window is proposed. Finally, a case study of a propeller aircraft system is conducted to verify the proposed model. It proves superior to the traditional OM and other models in terms of cost and OR.

Suggested Citation

  • Lu, Yaohui & Wang, Shaoping & Zhang, Chao & Chen, Rentong & Dui, Hongyan & Mu, Rui, 2024. "Adaptive maintenance window-based opportunistic maintenance optimization considering operational reliability and cost," Reliability Engineering and System Safety, Elsevier, vol. 250(C).
    • Handle: RePEc:eee:reensy:v:250:y:2024:i:c:s0951832024003648
    DOI: 10.1016/j.ress.2024.110292
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    References listed on IDEAS

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    2. Bokrantz, Jon & Subramaniyan, Mukund & Skoogh, Anders, 2025. "Seizing opportunity: Advancing the science and practice of opportunistic maintenance in manufacturing," International Journal of Production Economics, Elsevier, vol. 288(C).
    3. He, Zhichao & Wang, Yanhui & Sun, Wanhua & Hao, Yucheng & Xia, Weifu, 2025. "A proactive opportunistic maintenance decision model based on reliability in train systems," Reliability Engineering and System Safety, Elsevier, vol. 255(C).
    4. Zhang, Yadong & Wang, Shaoping & Zio, Enrico & Zhang, Chao & Dui, Hongyan & Chen, Rentong, 2025. "Multi-objective maintenance strategy for complex systems considering the maintenance uncertain impact by adaptive multi-strategy particle swarm optimization," Reliability Engineering and System Safety, Elsevier, vol. 256(C).
    5. Zhang, Chao & Qiao, Jingming & Wang, Shaoping & Chen, Rentong & Dui, Hongyan & Zhang, Yuwei & Bao, Yunpeng & Zhou, Yulong, 2025. "Importance measures based on system performance loss for multi-state phased-mission systems," Reliability Engineering and System Safety, Elsevier, vol. 256(C).
    6. Luo, Jiaxuan & Luo, Xiaofang & Ma, Xiandong & Zan, Yingfei & Bai, Xu, 2025. "An integrated condition-based opportunistic maintenance framework for offshore wind farms," Reliability Engineering and System Safety, Elsevier, vol. 256(C).
    7. Zhang, Chao & Zeng, Qi & Dui, Hongyan & Chen, Rentong & Wang, Shaoping, 2025. "Reliability model and maintenance cost optimization of wind-photovoltaic hybrid power systems," Reliability Engineering and System Safety, Elsevier, vol. 255(C).
    8. Meng, Yinghao & Qi, Faqun & Liu, Bowen & Yin, Zhen & Ye, Shuwen & Zhang, Haosen, 2025. "Joint optimization of maintenance strategy and buffer capacity for a multi-state buffered serial system considering self-repair actions," Reliability Engineering and System Safety, Elsevier, vol. 262(C).

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