Optimization of Condition-Based Maintenance With Multiple Times of Component Reallocation Using Markov Decision Process

Consider a system consisting of multistate components that perform the same function, and each component occupies a location in the system. The deterioration processes of components differ due to different workloads, usage rates, or environmental stresses that are associated with the locations. This article proposes a condition-based maintenance policy, in which the component reallocation (CR) with distinct assignments of components to locations and the preventive replacement of system are dynamically implemented based on the system state. A Markov decision process (MDP) is formulated to optimize the proposed condition-based multi-CR maintenance policy by determining the actions for each system state that minimize the expected long-run system maintenance cost. In the current studies on the MDP for maintenance optimization, the actions mainly include component replacement, imperfect repair, and system replacement. In this article, including CRs of distinct assignments as actions and considering multiple times of CRs increase the action space of the MDP significantly. An enumeration-based value iteration algorithm and a genetic-algorithm-based value iteration algorithm are proposed. Numerical experiments on k-out-of-n:G systems and Monte Carlo simulation tests show the effectiveness of CRs on reducing the system maintenance cost and extending system lifetime and provide structural insights on the optimal maintenance policy. © 2023 IEEE.