Hybrid Preventive Maintenance Optimization in Converter Furnaces: A Simulation and Fuzzy TOPSIS Approach(Case Study: Sarcheshmeh Copper Complex Smelting Plant)
Keywords:
Preventive maintenance; Reliability analysis; Simulation modeling; Fuzzy TOPSIS; Multi-criteria decision-making; Converter furnaces; Industrial optimizationAbstract
The objective of this study was to optimize preventive maintenance strategies for converter furnaces by integrating simulation modeling with fuzzy multi-criteria decision-making to identify the most reliable and cost-effective configuration. This research employed an applied design combining discrete-event simulation in AnyLogic with fuzzy TOPSIS analysis. Four operational scenarios (A1–A4) were developed to represent different configurations of local and imported refractory bricks in converter furnaces. Simulation models captured operational cycles, downtime, repair overlaps, and production outputs under stochastic failure conditions. The fuzzy TOPSIS method was then applied to rank scenarios based on multiple weighted criteria, including reliability, cost efficiency, and compliance with the operational constraint of maintaining three active furnaces at all times. Data inputs included historical operational records, repair times, and expert evaluations expressed as fuzzy triangular numbers. The simulation results revealed that hybrid configurations outperformed fully local or fully imported setups by reducing repair overlaps and maintaining production continuity. Fuzzy TOPSIS analysis ranked A2 as the most effective scenario with the highest closeness coefficient (0.953), followed by A4 (0.812) and A3 (0.711), while A1 performed least effectively (0.691). These inferential findings confirm that selective integration of local and imported resources enhances both reliability and cost optimization. The study concludes that hybrid preventive maintenance strategies, supported by simulation modeling and fuzzy multi-criteria decision-making, offer superior outcomes in complex industrial environments.
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Copyright (c) 2026 Saad Abdi, Ali Bozorgi Amiri, Mohammad Sheikhalishahi, Seyed Mojtaba Sajadi (Author)
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