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Maintenance Strategies Selection Using

Fuzzy FMEA and Integer Programming
Pranav Sankpal

A. Andrew

Post-Graduate Student

BHEL PPPU, Thirumayam.

Dr. S. Kumanan
Professor

Department of Production Engineering

National Institute of Technology,
Tiruchirappalli.

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Introduction

Contents

Literature Analysis
Problem Statement
Objectives
Proposed Model
Case study
Conclusion
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Introduction
Efficient maintenance planning is important for
achieving higher productivity levels.
Maintenance cost is one of the significant component
of operational expenditure.
Selection of right maintenance strategy is critical
because it determines future maintenance related
direct and indirect costs.

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Literature Analysis
Pariazar et al. (2008) combined factorial analysis and the analytic
hierarchic process (AHP), (improved by means of rough set theory) and
first recognized 19 effective criteria in maintenance strategy selection.
Shyjith et al. (2008) proposed the combination of AHP and TOPSIS to
select the suitable maintenance policy for a textile spinning mill ring
frame unit.
Mousavi et al. (2009) used factorial analysis for clustering many decision
making criteria into groups. Then they applied a fuzzy technique for order
preference by similarity to ideal solution (TOPSIS) method to help
decision makers to select the most appropriate maintenance strategy.
Arunraj and Maiti (2010) presented an approach to maintenance policy
selection based on the combined use of AHP and goal programming.
Braglia, M., Castellano, D. and Frosolini, M.(2013) proposed
an integer programming approach to maintenance strategies
selection to optimally allocate the budget monetary resources and
maximise the potential reduction of the RPN
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Problem Statement
Aim is to select most effective combination
maintenance strategies for an industrial equipment.

of

Currently FMEA is widely used tool for failure mode

prioritisation
All the maintenance activities are directed towards
critical failure.
Hence criticality evaluation is the most important part of
the model
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Limitations of traditional FMEA:

Criticality analysis is not realistic
Selection of maintenance strategies is very qualitative
and does not consider costs associated with maintenance
strategy and their effectiveness.
First limitation is addressed using fuzzy logic system
Problem of selecting optimum mix of maintenance
strategies subject to budget constrain is resolved using
integer programming.
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Objectives
To develop fuzzy logic system for realistic estimation of
criticality of each failure mode.
To select optimum mix of maintenance strategies taking
into account budget constraint and compatibility
constraint.

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Proposed Model

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Integer Programming
Model
RCM prioritises various failure modes based on fuzzy
Risk Priority Numbers
Next step is to assign to each failure mode, a suitable
maintenance strategy in such a way that reduction in
RPN for all failure modes is maximised.
Problem is formulated as mixed-integer linear
programming model and solved using GAMS

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Case Study

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Continued..

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Continued..

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Optimum mix of maintenance

strategies

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Conclusion
The application of maintenance strategy can reduce the RPN
value of a failure mode.
The proposed model allows to choose a set of maintenance
strategies which will maximise total reduction in RPN for all
failures.
Also the major difficulty in realistic assessment of RPN value is
addressed using fuzzy logic system.
More refinement in cost estimation task is required to enhance
the utility of proposed model.
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