RESEARCH PAPER
Redundancy Allocation and Condition-Based Maintenance Optimization in Heterogeneous Multi-State Systems under Imperfect Monitoring and Maintenance
More details
Hide details
1
Industrial Engineering Department, Universidad Tecnica Federico Santa Maria, Chile
A – Conceptualization; B – Methodology; C – Software; D – Validation; E – Formal analysis; F – Investigation; G – Resources; H – Data curation; I – Writing – original draft; J – Writing – review & editing; K – Visualization; L – Supervision; M – Project administration; N – Funding acquisition
Submission date: 2026-03-12
Final revision date: 2026-05-31
Acceptance date: 2026-09-12
Online publication date: 2026-09-16
Corresponding author
Fredy Kristjanpoller
Industrial Engineering Department, Universidad Tecnica Federico Santa Maria, Valparaiso, Chile
KEYWORDS
TOPICS
ABSTRACT
Existing redundancy allocation and maintenance optimization models commonly neglect imperfect monitoring and maintenance conditions and often rely on sequential decision approaches. This study proposes a joint optimization framework for redundancy allocation and CBM in heterogeneous repairable multi-state weighted k-out-of-n systems. The objective is to minimize life-cycle cost while satisfying availability requirements under imperfect monitoring and maintenance conditions. Semi-Markov processes and universal generating functions are jointly used to model degradation, false alarms, missed detections, maintenance delays, and imperfect preventive actions. An adapted GA identifies high-quality feasible solutions under strict availability requirements. Results show that explicitly modeling imperfections reduces life-cycle cost by about 13%, while a sequential scheme increases cost by about 7% compared with the joint formulation. Sensitivity analyses reveal that demand and repair duration strongly affect performance and require joint adaptation of thresholds and redundancy.
REFERENCES (52)
1.
Huang S, Lei B, Gao K, Wu Z, Wang Z. Multi-state system reliability evaluation and component allocation optimization under multi-level performance sharing. IEEE Access 2021; 9: 88820-34.
https://doi.org/10.1109/ACCESS....
2.
Eryilmaz S. Reliability analysis of multi-state system with three-state components and its application to wind energy. Reliability Engineering & System Safety 2018; 172: 58-63.
https://doi.org/10.1016/J.RESS....
3.
Huang T, Xiahou T, Li Y-F, Qian H-M, Liu Y, Huang H-Z. Reliability assessment of wind turbine generators by fuzzy universal generating function. Eksploatacja i Niezawodność – Maintenance and Reliability 2021; 23: 308-14.
https://doi.org/10.17531/ein.2....
4.
Cui X, Li T, Wang S, Shi J, Ma Z. Reliability modeling based on power transfer efficiency and its application to aircraft actuation system. Eksploatacja i Niezawodność – Maintenance and Reliability 2020; 22: 282-96.
https://doi.org/10.17531/ein.2....
5.
Chen Z, Zhao T, Jiao J, Ren F. Availability analysis and optimal design of multistate weighted k -out-of- n systems with component performance requirements. IEEE Access 2018; 6: 51547-55.
https://doi.org/10.1109/ACCESS....
6.
Li S, Yang Z, Fang C, Luo H, He J, Li J, et al. Optimal maintenance strategy for imperfect manufacturing system considering operational availability under delay propagation. Eksploatacja i Niezawodność – Maintenance and Reliability 2026; 28(1): 207148.
https://doi.org/10.17531/ein/2....
7.
Lisnianski A, Levitin G. Multi-state system reliability: Assessment, optimization and applications. World scientific; 2003.
8.
Sharifi M, Taghipour S. Inspection interval optimization of a weighted-k-out-of-n system with identical multi-state load-sharing components. Reliability Engineering & System Safety 2023; 238: 109412.
https://doi.org/10.1016/J.RESS....
9.
Tian Z, Levitin G, Zuo MJ. A joint reliability–redundancy optimization approach for multi-state series–parallel systems. Reliability Engineering & System Safety 2009; 94: 1568-76.
https://doi.org/10.1016/J.RESS....
10.
Fyffe DE, Hines WW, Lee NK. System reliability allocation and a computational algorithm. IEEE Transactions on Reliability 1968; R-17: 64-9.
https://doi.org/10.1109/TR.196....
11.
Attar A, Raissi S, Khalili-Damghani K. A simulation-based optimization approach for free distributed repairable multi-state availability-redundancy allocation problems. Reliability Engineering & System Safety 2017; 157: 177-91.
https://doi.org/10.1016/J.RESS....
12.
Li XY, Li YF, Huang HZ. Redundancy allocation problem of phased-mission system with non-exponential components and mixed redundancy strategy. Reliability Engineering & System Safety 2020; 199: 106903.
https://doi.org/10.1016/J.RESS....
13.
Kim H. Markov-based reliability model for a mixed redundant system and parallel genetic algorithm with knowledge archives for a redundancy allocation problem. Reliability Engineering & System Safety 2023; 240: 109585.
https://doi.org/10.1016/J.RESS....
14.
Li J, Xue L, Wang G, Zhou H. Availability evaluation and design optimization of multi-state k-out-of-n: G systems with random performance requirements. IEEE Access 2023; 11: 119106-17.
https://doi.org/10.1109/ACCESS....
15.
Sharifi M, Taghipour S. Redundancy allocation problem with a mix of components for a multi-state system and continuous performance level components. Reliability Engineering & System Safety 2024; 241: 109632.
https://doi.org/10.1016/J.RESS....
16.
Mobley RK. An introduction to predictive maintenance. Elsevier; 2002.
17.
Guiras Z, Turki S, Rezg N, Dolgui A. Optimal maintenance plan for two-level assembly system and risk study of machine failure. International Journal of Production Research 2019; 57: 2446-63.
https://doi.org/10.1080/002075....
19.
Jardine AKS, Lin D, Banjevic D. A review on machinery diagnostics and prognostics implementing condition-based maintenance. Mechanical Systems and Signal Processing 2006; 20: 1483-510.
https://doi.org/10.1016/J.YMSS....
20.
Ahmad R, Kamaruddin S. An overview of time-based and condition-based maintenance in industrial application. Computers & Industrial Engineering 2012; 63: 135-49.
https://doi.org/10.1016/J.CIE.....
21.
Alaswad S, Xiang Y. A review on condition-based maintenance optimization models for stochastically deteriorating system. Reliability Engineering & System Safety 2017; 157: 54-63.
https://doi.org/10.1016/J.RESS....
22.
Andersen JF, Nielsen BF. A comparative study of time-based maintenance and condition-based maintenance for multi-component systems. Reliability Engineering & System Safety 2025; 256: 110759.
https://doi.org/10.1016/J.RESS....
23.
Castro IT, Basten RJI, Houtum GJ van. Maintenance cost evaluation for heterogeneous complex systems under continuous monitoring. Reliability Engineering & System Safety 2020; 200: 106745.
https://doi.org/10.1016/J.RESS....
24.
Oakley JL, Wilson KJ, Philipson P. A condition-based maintenance policy for continuously monitored multi-component systems with economic and stochastic dependence. Reliability Engineering & System Safety 2022; 222: 108321.
https://doi.org/10.1016/J.RESS....
25.
Zhang F, Liao H, Shen J, Ma Y. Optimal maintenance of a system with multiple deteriorating components served by dedicated teams. IEEE Transactions on Reliability 2023; 72: 900-15.
https://doi.org/10.1109/TR.202....
26.
Tang X, Xiao H, Kou G, Peng R. Optimal inspection policy for a three-stage system with imperfect inspection and repair. IEEE Transactions on Reliability 2024; 73: 1669-83.
https://doi.org/10.1109/TR.202....
28.
Azadeh A, Asadzadeh SM, Salehi N, Firoozi M. Condition-based maintenance effectiveness for series–parallel power generation system—a combined markovian simulation model. Reliability Engineering & System Safety 2015; 142: 357-68.
https://doi.org/10.1016/J.RESS....
29.
Wu W, Prescott D, Remenyte-Prescott R, Saleh A, Ruano MC. An asset management modelling framework for wind turbine blades considering monitoring system reliability. Reliability Engineering & System Safety 2024; 252: 110478.
https://doi.org/10.1016/J.RESS....
30.
Xu Y, Pi D, Yang S, Zio E. Knowledge transfer-based multifactorial evolutionary algorithm for selective maintenance optimization of multistate complex systems. IEEE Transactions on Reliability 2024; 73: 1341-52.
https://doi.org/10.1109/TR.202....
31.
Kocer Ozturk M, Khaniyev T. Optimal maintenance policy for a markov deteriorating system under reliability limit. Eksploatacja i Niezawodność – Maintenance and Reliability 2024; 26: 190865.
https://doi.org/10.17531/ein/1....
32.
Zhang W, Zhang X, He S, Zhao X, He Z. Optimal condition-based maintenance policy for multi-component repairable systems with economic dependence in a finite-horizon. Reliability Engineering & System Safety 2024; 241: 109612.
https://doi.org/10.1016/J.RESS....
33.
Liu L, Zhao G, Sun Y, Hu W. Reliability analysis method of a repairable system with delay and correlation maintenance. 2020 Prognostics and Health Management Conference (PHM-Besançon), IEEE; 2020, p. 132–6.
https://doi.org/10.1109/PHM-Be....
34.
Zhao X, He S, He Z, Xie M. Optimal condition-based maintenance policy with delay for systems subject to competing failures under continuous monitoring. Computers & Industrial Engineering 2018; 124: 535-44.
https://doi.org/10.1016/j.cie.....
35.
Eryilmaz S. The number of failed components in a k-out-of-n system consisting of multiple types of components. Reliability Engineering & System Safety 2018; 175: 246-50.
https://doi.org/10.1016/J.RESS....
36.
Hamdan K, Tavangar M, Asadi M. Optimal preventive maintenance for repairable weighted k-out-of-n systems. Reliability Engineering & System Safety 2021; 205: 107267.
https://doi.org/10.1016/J.RESS....
37.
Liu Y, Huang H-Z, Wang Z, Li Y, Yang Y. A joint redundancy and imperfect maintenance strategy optimization for multi-state systems. IEEE Transactions on Reliability 2013; 62: 368-78.
https://doi.org/10.1109/TR.201....
38.
Hao Y, Zhu X. Redundancy design and preventive maintenance for a load-sharing multiasset system considering uncertain environmental conditions. IEEE Transactions on Industrial Informatics 2024; 20: 9308-19.
https://doi.org/10.1109/TII.20....
39.
Kristjanpoller F, Cárdenas-Pantoja N, Viveros P, Pascual R. Wind farm life cycle cost modelling based on oversizing capacity under load sharing configuration. Reliability Engineering & System Safety 2023; 236: 109307.
https://doi.org/10.1016/J.RESS....
40.
Limnios N. Reliability measures of semi-markov systems with general state space. Methodology and Computing in Applied Probability 2012; 14: 895-917.
https://doi.org/10.1007/s11009....
41.
Distefano S, Trivedi KS. Non‐markovian state‐space models in dependability evaluation. Quality and Reliability Engineering International 2013; 29: 225-39.
https://doi.org/10.1002/qre.13....
42.
Bisht V, Singh SB. Lz‐transform approach to evaluate reliability indices of multi‐state repairable weighted k‐out‐of‐n systems. Quality and Reliability Engineering International 2023; 39: 1043-57.
https://doi.org/10.1002/qre.32....
43.
Gu L, Wang G, Zhou Y, Peng R. Reliability optimization of multi-state systems with two performance sharing groups. Reliability Engineering & System Safety 2024; 241: 109580.
https://doi.org/10.1016/J.RESS....
44.
Ushakov IA. A universal generating function. Soviet Journal of Computer and Systems Sciences 1986; 24: 37.
45.
Li YF, Zio E. A multi-state model for the reliability assessment of a distributed generation system via universal generating function. Reliability Engineering & System Safety 2012; 106: 28-36.
https://doi.org/10.1016/J.RESS....
46.
Li W, Zuo MJ. Reliability evaluation of multi-state weighted k-out-of-n systems. Reliability Engineering & System Safety 2008; 93: 160-7.
https://doi.org/10.1016/J.RESS....
47.
Chern MS. On the computational complexity of reliability redundancy allocation in a series system. Operations Research Letters 1992; 11: 309-15.
https://doi.org/10.1016/0167-6....
48.
Peiravi A, Nourelfath M, Zanjani MK. Redundancy strategies assessment and optimization of k-out-of-n systems based on markov chains and genetic algorithms. Reliability Engineering & System Safety 2022; 221: 108277.
https://doi.org/10.1016/J.RESS....
49.
Gholinezhad H. A new model for reliability redundancy allocation problem with component mixing. Reliability Engineering & System Safety 2024; 242: 109815.
https://doi.org/10.1016/J.RESS....
50.
Zhang J, Li L, Chen Z. Strength–redundancy allocation problem using artificial bee colony algorithm for multi-state systems. Reliability Engineering & System Safety 2021; 209: 107494.
https://doi.org/10.1016/J.RESS....
51.
Kristjanpoller F, Michell K, Kristjanpoller W, Crespo A. Fleet optimization considering overcapacity and load sharing restrictions using genetic algorithms and ant colony optimization. AI EDAM 2020; 34: 104-13.
https://doi.org/10.1017/S08900....
52.
Oszczypała M, Konwerski J, Ziółkowski J, Małachowski J. Reliability analysis and redundancy optimization of k-out-of-n systems with random variable k using continuous time markov chain and monte carlo simulation. Reliability Engineering & System Safety 2024; 242: 109780.
https://doi.org/10.1016/J.RESS....