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For engineering and production systems, due to the structural dependence between components, the disassembly operation caused by the replacement of components will affect the failure and degradation processes of other components in the system. In order to optimize the extended warranty (EW) cost of the multi‐component system with structural dependence, this paper described the structural dependence and modeled the disassembly operation impact, and then the failure rate model of the component considering the impact of disassembly operation under EW was developed. Combined with the actual situation, a condition-based maintenance (CBM) strategy was employed to construct the EW cost model of the multi‐component system with structural dependence. Monte Carlo simulation was proposed to determine the optimal EW cost of the system and the optimal periodic inspection interval of the CBM strategy. Finally, a numerical example of the planetary gear train of an automobile generator is introduced to demonstrate the feasibility and advantages of the proposed model in EW cost optimization and the analysis of disassembly operation impact on the optimal maintenance strategy.

Condition-Based Maintenance Modeling and Reliability Assessment for Multi-Component Systems with Structural Dependence under Extended Warranty