A State-Age-Dependent Maintenance-Spare Control Strategy Under Inspection Error Compensation

Inspection errors are extensively reported in equipment health management due to multisource noises and technical limitations, particularly in hidden defect diagnosis of the multistage failure process. This article proposes a state-age-dependent maintenance and spare control strategy to compensate inspection-error-induced risk (attributed to both false positive and false negative) during defect identification. Specifically, a dual-phase adaptive inspection accommodating health variation is scheduled, following which both spare ordering and replacement are postponed to compensate implication of false-positive error. In addition, age-based replacement supported by preponed standard ordering is implemented promptly to alleviate false-negative error impact. To mitigate downtime losses, a dynamic selection mechanism upon failure occurrence between urgent and standard orderings is executed. The long-run operational cost rate is minimized by the joint optimization of postponed intervals of ordering and replacement, as well as the second-phase inspection interval. The model applicability is demonstrated through numerical experiments conducted on high-speed train bogie bearings.