Optimization of Two-Dimensional Extended Warranty Scheme for Failure Dependence of a Multi-Component System with Improved PSO–BAS Algorithm

Abstract

Human society is entering the era of Industry 4.0; engineering systems are becoming more complex, which increases the difficulties of maintenance support work. Failure dependence exists widely in multi-component systems. In this work, a model of two-dimensional (2D) warranty decision making was constructed by using a failure-dependence analysis for multi-component systems and by considering the extended warranty cost and the system availability. The decision was to cut the warranty cost as much as possible for manufacturers, while the constraint condition was the minimum acceptable availability for the customer. The model combined preventive maintenance as well as corrective maintenance strategies. Under the condition that the multi-component system is replaced upon the expiration of the extended warranty (EW), the optimal 2D EW duration and preventive maintenance interval could be obtained through the model. In a case analysis, the optimal EW scheme for the gearbox of an electric multiple unit (EMU) system was obtained by using a grid search algorithm, a PSO algorithm, and a PSO–BAS algorithm. Through comparison, the PSO–BAS algorithm obtained a better scheme with lower warranty costs and higher system availability. A comparative analysis and a sensitivity analysis showed that the model provides a theoretical basis for manufacturers to optimize their 2D extended gearbox warranties.