1 Introduction
System reliability analysis and optimization are important to utilize available resources and part types efficiently and to develop the preferred or optimal system design architecture. The roots of the mathematical treatment of optimization problems can be traced even in Antiquity (Žilinskas and Zhigljavsky,
2016). In recent years, reliability and availability have expanded their influence in various industries and fields, thus these concepts serve as essential quality elements in many systems. Allocating redundant elements in the subsystems has been recognized as an effective means to meet the system reliability or availability requirement. The RAP problem is the problem of finding an optimal allocation of redundant components subject to a set of resource constraints (Caserta and Voß,
2015). It is one of the best-developed problems in reliability engineering studies. The RAP, which involves choosing appropriate elements and placing them redundantly to form an optimal system structure with high reliability and low cost, has received much attention in the literature. This essential problem has many applications in the real-world systems, such as production systems design, etc. The optimal reliability design aims to determine a system structure that achieves higher levels of reliability by exchanging the existing components with more reliable components or/and using redundant components.
Researchers have studied this problem from many different perspectives (Kuo and Wan,
2007; Yeh and Hsieh,
2011). The RAP is commonly considered in a multi-criteria decision-making (MCDM) environment, which has many applications in engineering problems (Keshavarz Ghorabaee,
2016; Keshavarz Ghorabaee
et al.,
2014). MCDM problems are generally divided into two classes: multi-objective decision-making (MODM) methods and multi-attribute decision-making (MADM) methods. MODM methods are generally used for dealing with the RAP. The traditional objectives for the RAP are maximizing the reliability and minimizing the cost of the system. Both of these objectives are increased by including more components. This trade-off requires the problem to be evaluated in the multi-objective context. In multi-objective problems, a set of non-dominated Pareto optimal solutions are obtained instead of a single optimal solution (Radziukynienė and Žilinskas,
2014). Data perception is frequently a complex problem, especially when data point to a complicated phenomenon described by many parameters, i.e. multidimensional data are analysed (Dzemyda
et al.,
2013). The estimation of intrinsic dimensionality of high-dimensional data still remains a challenging issue (Karbauskaitė and Dzemyda,
2015,
2016). Various methods are used to determine the Pareto optimal solutions of a multi-objective problem. The
ε-constraint is one of the MODM methods that can be applied to find them (Soylu and Kapan Ulusoy,
2011). One of early program realizations of MODM methods is the system MOP (Dzemyda and Šaltenis,
1994).
System availability, a concept closely related to reliability, refers to the scale of measuring the reliability of a repairable system. The repairable system indicates a system that can be repaired to operate normally in the event of any failure. When the time-to-repair (TTR) is not negligible in relation to the operational time, system’s reliability is measured by its availability (Høyland and Rausand,
2004).
RAP is a challenging subject which has attracted the attention of many authors. Generally, in the RAP there are two strategies for using the redundant components: active and standby (Ardakan
et al.,
2015).
Generally, there are two types of the redundancy allocation problems. In the first type, we deal with discrete component choices with predefined characteristics (reliability, cost, weight, etc.). The aim of solving the problems in this type is choosing the components and the corresponding redundancy levels. In the second type, component reliability or a distribution parameter is treated as a design variable, and component cost is a known increasing function of component reliability (Coit and Liu,
2000). The majority of works in the first type have focused on the reliability of non-repairable systems. Using the metaheuristics is the most common approach for dealing with this problem because the RAP is an NP-hard problem and the computational time of optimal algorithms for the NP-hard problems is exponentially increased by enlarging the size of the problem (Amiri
et al.,
2014; Chern,
1992). Gupta
et al. (
2009) considered the problem of constrained redundancy allocation of the series system with interval valued reliability of components. They formulated the problem as an unconstrained integer programming problem with interval coefficients by penalty function technique and solved it by an advanced genetic algorithm (GA). Beji
et al. (
2010) proposed a hybrid algorithm based on particle swarm optimization and local search algorithm for the RAP. In addition, they introduced an adaptive penalty function for encouraging the algorithm to explore the feasible and near feasible region. Zhang
et al. (
2014) proposed a practical approach, combining bare-bones particle swarm optimization and sensitivity-based clustering for solving multi-objective reliability redundancy allocation problems. Wang and Li (
2014) advanced a meta-heuristic approach called particle swarm optimization and applied it to obtain near-optimal solutions of the RAP in the multi-state systems with bridge topology. Keshavarz Ghorabaee
et al. (
2015) considered a RAP related to a system of
s independent
k-out-of-
n subsystems in series. Maximization of the system reliability and minimization of the system cost were the objectives of the problem. They proposed four multi-objective genetic algorithms to handle this problem. It should be said that the current study is also related to the first type of the redundancy allocation problems.
Ardakan and Hamadani (
2014) applied the mixed-integer non-linear optimization of reliability–redundancy allocation problem. Later, Abouei Ardakan
et al. (
2016) presented a new interpretation and formulation of the reliability–RAP and compared solution with traditional approaches.
Most of the studies for availability maximization have pertained to the second class of problems. There are few researches on availability of repairable systems that belong to the first type of problems. Castro and Cavalca (
2003) presented an availability optimization problem of an engineering system assembled in a series configuration which has the redundancy of units and teams of maintenance as optimization parameters and developed a genetic algorithm to solve this problem. Zoulfaghari
et al. (
2014) studied a bi-objective RAP for a system with mixed repairable and non-repairable components. They proposed a new mixed integer nonlinear programming (MINLP) model to analyse this problem and used an efficient genetic algorithm to solve it. Lins and Droguett (
2011) proposed a multi-objective genetic algorithm (GA) coupled with discrete event simulation to solve redundancy allocation problems in systems subjected to imperfect repairs. They validated the multi-objective GA via examples with analytical solutions and showed its superior performance when compared to a multi-objective ant colony algorithm (ACO).
The majority of these studies have considered systems that involve components with constant failure and repair rates. In these cases, time-to-failure (TTF) and time-to-repair (TTR) of the components have an exponential distribution. The hypotheses of constant failure rates are rarely met in real situations and may reduce the estimation accuracy of the entire system reliability or availability. In the classical system reliability theory, problems with such features are usually handled by a Markovian model. If we consider a system with components that have other distributions (e.g. Gamma, Normal, Weibull, etc.) for TTF and TTR, we cannot usually use an analytical method to obtain the system availability. In this study, we propose a new approach to design a system with the components that could have any distribution for their TTF and TTR.
The flexibility given by the simulation enables us to interpret many real aspects in problem modelling. Simulation is especially useful in situations where an analytical treatment is not utilizable (Lins and Droguett,
2009). A simulation model is a causal model of a real system. A meta-model is an approximation of the input/output (I/O) transformation that is implied by the simulation model. There are different types of meta-models such as polynomial regression models, splines, neural networks, etc. (Kleijnen and Sargent,
2000). Many researchers have developed meta-model-based approaches for optimization engineering problems. Aytug
et al. (
1996) proposed a method optimizing the number of kanbans in a pull production system by using simulation meta-modelling. Through meta-modelling, they determined the relationship between the number of kanbans and the average time to fill a customer order. Yang and Tseng (
2002) introduced a new approach to optimize throughput and cycle time performance of integrated circuit ink-marking machines based on a simulation meta-model, a hybrid response surface method, and lexicographical goal programming approach. Noguera and Watson (
2006) developed a general simulation meta-model in a particular company of chemicals industry in order to understand better how plant design parameters could be optimized in order to maximize plant throughput under certain environmental conditions and with certain asset investment constraints. Wang and Shan (
2007) reviewed the meta-model-based techniques in supporting design optimization, including model approximation, design space exploration, problem formulation, and solving various types of optimization problems. Azadeh
et al. (
2010) presented an integrated approach based on simulation, meta-modelling using DOE and goal programming to solve the job shop scheduling problem with multiple objectives. Zakerifar
et al. (
2011) described the application of Kriging meta-modelling in multiple-objective simulation optimization. They utilized a simulation model of an
$(s,S)$ inventory system to demonstrate the capabilities of Kriging meta-modelling as a simulation tool. Amiri and Mohtashami (
2012) proposed a multi-objective formulation of the buffer allocation problem in unreliable production lines. They used a factorial design which has to build a meta-model for estimating production rate based on simulation. A genetic algorithm was utilized for solving the model and determining the optimal (or near optimal) size of each buffer storage.
In this research, we consider a bi-objective RAP in a series-parallel repairable system. Maximization of the system steady-state availability and minimization of the system cost are the objectives of the problem, and the system is constrained by a predefined weight. Although the TTF and TTR of the components could have any distribution in the proposed approach, we consider an example where the components’ TTF and TTR follow Gamma distribution. The Gamma distribution is considered because it is a flexible one and it can be used to model increasing, decreasing, and constant failure rates, similarly to the Weibull distribution. Moreover, it can be used to approximate several component failure time distributions (Amari,
2012). Also, this distribution has an important application for modelling the distribution of the TTF of a component, subjected to shocks whose arrivals follow a homogeneous Poisson process with intensity lambda. If the component is subjected to partial damage or degradation by each shock and fails completely at the
k-th shock, the distribution of the time to failure of the component is given by the Gamma distribution (Modarres
et al.,
2009).
In the proposed approach, the steady-state availability of each subsystem in the series-parallel system is evaluated with an individual meta-model. The design of experiment, simulation, and the stepwise regression are used to build meta-models for calculating an approximation of the steady-state availability of each subsystem. In other words, steady-state availability of each subsystem is the response of the experiments and redundancy levels are the factors of them. Besides cost objective function, created meta-models are considered in the mathematical model using a max–min approach. The augmented ε-constraint method is utilized for obtaining the Pareto (near-Pareto) optimal solutions to this problem.
The rest of this paper is organized as follows. In Section
2, we show the general and max–min formulations of the RAP for the series-parallel systems. In Section
3, we describe the proposed approach in detail. In Section
4, we use an illustrative example to represent the performance of the proposed approach. The conclusions are discussed in Section
5.