Large-scale benchmarking of multi-objective soft-computing metaheuristics for redundancy allocation in repairable k-out-of-n systems

This paper presents a large-scale budget-aware benchmark of multi-objective soft-computing metaheuristics for a bi-objective redundancy allocation problem in repairable k-out-of-n systems. The problem combines cost minimization and steady-state availability maximization under weight constraints, with binary subsystem-level decisions determining both the number of redundant components and the redundancy strategy. Four strategies are considered: cold standby, warm standby, hot standby, and a mixed active-warm standby strategy. Subsystem availability is evaluated using continuous-time Markov chains, while the optimization task is treated as a constrained mixed-integer multi-objective problem. The study compares 65 metaheuristic algorithms from multiple algorithmic families under two initialization settings, with and without Scaled Binomial Initialization (SBI), across six case studies of increasing structural and dimensional complexity and four weight limits per case. Performance is assessed using hypervolume, budget-dependent convergence profiles, and non-parametric statistical comparisons. The results show that algorithm rankings are strongly budget-dependent, indicating that a single final-budget ranking can be misleading. SBI provides a substantial early advantage and can change the relative performance of competing methods, especially for larger instances. The best-performing algorithms vary across budget regimes: NNIA-SBI and CMOPSO-SBI are competitive under tight budgets, whereas NSGA-II+ARSBX-SBI performs robustly for medium and large budgets. From a system design perspective, Pareto-optimal solutions are dominated by hot standby and mixed redundancy strategies, while cold and warm standby rarely appear. The benchmark highlights the importance of initialization, computational budget, and problem complexity when selecting soft-computing optimizers for practical redundancy allocation.