Condition-Based Maintenance Planning for Systems Subject to Dependent Soft and Hard Failures

Most systems can fail in multiple ways, and the failure modes are usually positively correlated. This phenomenon complicates the reliability analysis and makes the corresponding maintenance planning challenging. This article proposes a condition-based maintenance policy for systems that are subject to both degradation-induced soft failure and sudden hard failure, where a higher degradation level leads to a higher hazard rate of the hard failure. The Wiener process is adopted for the degradation process, and the Weibull model is used to describe the baseline hazard rate of the hard failure. The degradation level is then treated as a time-varying covariate that affects the hazard rate of the hard failure, and the closed-form of the reliability function is derived by using the Brownian bridge theory. An inspection/replacement maintenance policy is employed, and the long-run cost rate is formulated based on the semiregenerative property of the system state. The optimal inspection interval and the preventive replacement threshold are then jointly determined by minimizing the long-run cost rate. A numerical study on a hydraulic sliding spool system is conducted to validate the derived reliability function and the maintenance policy.