Performance modeling and optimization for the stock preparation unit of a paper plant using genetic algorithm

Purpose – This paper aims to deal with the performance modeling and optimization for the stock preparation unit of a paper plant using genetic algorithm. It provides the optimum unit availability level for different combinations of failure and repair rates of the subsystems of the stock preparation unit of the paper plant concerned. Design/methodology/approach – Efforts have been made to develop the performance model based on a real situation for the stock preparation unit. The performance in terms of availability has been evaluated on the basis of Markov birth‐death process. After that, the performance optimization using genetic algorithm is performed, which gives the optimum unit availability levels for different combinations of failure and repair rates of the subsystems of stock preparation unit for enhancing the overall performance of the paper plant. Findings – The effect of genetic algorithm parameters such as number of generations, population size and crossover probability on the unit performance, i.e. availability, has been analyzed and discussed with the concerned paper plant management. It is found that these results are highly beneficial to the maintenance engineers for the purpose of the effective maintenance planning to enhance the overall performance (availability) of stock preparation unit of the paper plant. Originality/value – Most other researchers have confined their work to the development and analysis of theoretical models which has little practical significance. To fulfill this deficiency, efforts have been made in the present work to develop a model based on real situation for stock preparation unit.