A robust design for lifecycle cost with reliability analysis integration

Maintenance, repair, and overhaul (MRO) is the most significant cost driver over a complex engineering asset lifecycle. Therefore, high-value manufacturers are required to plan MRO occurrences to optimize the overhaul cost while achieving the desired performance. This trade-off imposes a shift towards a proactive maintenance strategy. However, creating a long-term proactive maintenance plan is challenging due to uncertainties in the performance of the asset and its critical components. Hence, this paper presents a robust design framework for the lifecycle cost estimation process by integrating reliability life data analysis. The level of data availability across the lifecycle is considered. The framework is proposed based on a literature review and the Delphi method. This study highlights that the level of robustness in the lifecycle cost estimates can be achieved by continuous feedback to the design phase and to the body of knowledge over the asset lifecycle. Moreover, this study suggests that the optimization model for the trade-off between cost and reliability should fulfil safety and environmental sustainability requirements when providing a cost-effective reliability solution.