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ABSTRACT
The growth of world-class manufacturing companies and global competition caused significant
changes in the manufacturing companies operations. These changes have affected maintenance and
made its role even more crucial to stay ahead of the competition. Maintenance strategy selection is
one of the strategic decision-making issues that manufacturing companies in the current competitive
world are facing. In this paper, a comparison between different Multiple Criteria Decision Making
(MCDM) approaches is conducted in a dairy manufacturing factory to rank the maintenance strategies.
The aim is to suggest an appropriate approach for the best selection of the maintenance strategy. The
decision-making elements including evaluation criteria/sub-criteria and problem alternatives, i.e.,
maintenance strategies are determined and a group of experts from the case-study factory are asked
to make their pair-wise comparisons. The pair-wise comparison matrix is constructed by using the
crisp and triangular fuzzy numbers, while the aggregation of individual priorities (AIP) approach is
utilized to aggregate the decision-makers’ judgments. The priority vectors of decision elements are
calculated by Mikhailov’s fuzzy preference programming (FPP) methods and the final weights of the
decision elements are found. Results show that when the effectiveness of one element on the other
elements is higher, it will have greater weights; and therefore, the results from the analytic network
process (ANP) method is completely different from those of the analytic hierarchy process (AHP).
The reason for the differences between the AHP and Fuzzy AHP (FAHP) with the ANP and Fuzzy
ANP (FANP) is that both AHP and FAHP evaluate the criteria only based on the level of importance
and do not consider the interdependencies and interactions among the evaluation elements. In this
research, a predictive maintenance is selected as the most appropriate strategy in the case company
and the preventive strategies outperformed the corrective strategies. The results of this research are
consistent with the results of previous studies found in the literature.
Keywords
Analytical Hierarchy Process (AHP), Analytical Network Process (ANP), Fuzzy Set Theory, Maintenance
Strategy Selection, Multi-Criteria Decision Making
DOI: 10.4018/IJSDS.2016070103
Copyright © 2016, IGI Global. Copying or distributing in print or electronic forms without written permission of IGI Global is prohibited.
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1. INTRODUCTION
In the past, many companies considered maintenance as an inevitable source of cost. For these
companies, maintenance operations have a corrective function (fix it on failure) and are only executed
in emergency conditions. Today, this form of intervention is not acceptable because of certain critical
elements such as product quality, plant safety, and increased costs of maintenance departments
(Bevilacqua and Braglia, 2000). Furthermore, in the current competitive world, manufacturing firms
attempt to improve their performance in terms of cost, quality, and flexibility, in an effort to compete
with other firms of the global marketplace (Ertugrul Karsak and Tolga, 2001). In the manufacturing
firms, various problems such as manufacturing technology selection, maintenance strategy selection,
machine location, and evaluation of quality function would influence production cost, product quality,
and product delivery-time (Bashiri, Badri, and Hejazi, 2011). As indicated by Mobley (2002), one
third of all of the maintenance costs are wasted as a result of unnecessary maintenance. The use
of inefficient maintenance policies considerably increases the direct maintenance costs (Rastegari
and Bengtsson, 2014). On the other hand, the manufacturing firms are under a great pressure to
continuously reduce their production costs. One of the main expenditure items for these firms is their
maintenance costs, which can comprise up to 15%-70% of the overall production costs according to
the type of industry (Bevilacqua and Braglia, 2000; Rastegari and Bengtsson, 2015).
In recent years, the importance of maintenance strategy selection has been increased due to the
critical role it has for increasing the availability, the safety, and the mean time to failures, improvement
of system reliability and product quality, reducing shutdown time of factory, and preventing
unnecessary investments. Various methodologies have been used for selecting a suitable maintenance
strategy in the literature as presented as follows. Triantaphyllou, et al. (1997) have suggested a method
to address criticality of the criteria related to the problem of maintenance strategy selection. They first
prioritized the maintenance strategies using the AHP and then performed a sensitivity analysis on
different criteria to identify the most important one. The maintenance strategy selection was presented
by Luce (1999), Okumura and Okino (2003) based on different production loss and maintenance
costs incurred by different maintenance strategies. Azadivar and Shu (1999) proposed a method for
selecting an appropriate strategy for each class of systems in a just in time environment exploring
16 characteristic factors that could play a role in the maintenance strategy selection. Using the AHP
method for the maintenance strategy selection was suggested by Bevilacqua and Braglia (2000). Al-
Najjar and Alsyouf (2003) and Sharma, et al. (2005) evaluated the maintenance strategies through the
fuzzy interference system (FIS) and the fuzzy multi-criteria decision-making methods. Mechefske
and Wang (2003) used the fuzzy linguistic variables to evaluate and select the optimum maintenance
strategy and condition monitoring technique. Bertolini and Bevilacqua (2006) presented a combined
model based on the AHP and the goal programming (GP) to identify the best maintenance strategy
for the critical centrifugal pumps in an Italian oil refinery.
Wang, et al. (2007) evaluated different maintenance strategies based on the FAHP. In their study,
a new method is also proposed for obtaining the priorities from the fuzzy pair-wise comparisons
matrix. A combination of the FAHP and TOPSIS methods was utilized by Shyjith et al. (2008) to
select an optimum maintenance strategy for textile industries. Jafari, et al. (2008) applied a fuzzy
Delphi method in simple additive weighting (SAW) for the maintenance strategy selection which
could determine the best maintenance strategy by considering the uncertainty levels and considering
various maintenance criteria and their importance. Arunraj and Maiti (2010) used the combination
of AHP and GP for the maintenance strategy selection based on the risk of equipment failure and
the maintenance cost. They applied this approach in a case study in a benzene extraction unit of a
chemical plant. Cheng and Tsao (2010) suggested the ANP method to select an optimum maintenance
strategy for rolling stock in a railway system.
Bashiri et al. (2011) developed a new interactive method based on the fuzzy linear assignment
method for an efficient maintenance strategy selection which uses the quantitative and qualitative data
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for ranking the maintenance strategies. Jajimoggala et al. (2011) presented an integrated approach
for the maintenance policy selection based on fuzzy Analytic Network Process (ANP) and the Goal
Programming. Fouladgar et al. (2012) proposed a new fuzzy MCDM method based on the concepts
of COPRAS (Complex Proportional Assessment) and AHP (Analytical Hierarchy Process) to evaluate
the feasible maintenance strategy. In their study, Fuzzy AHP was utilized to calculate the weights of
the evaluation criteria; and COPRAS was applied to rank the alternatives. Zaim, et al. (2012) used
AHP and ANP methods in a case study to select best maintenance strategy in a local newspaper
printing facility in Turkey. We can mention Ferdousmakan at al. (2014) in recent studies in which
they integrated risk management and fuzzy analytical hierarchy process in order to select the optimal
maintenance strategy. They made a risk priority matrix that includes five different risk levels and
four criteria to investigate four possible maintenance strategies.
The main objective of the present study is to determine an appropriate approach for the
maintenance strategy selection. The rest of this paper is organized as follows. The methodology of this
study is introduced in Section 2. Section 3 describes implementing the proposed model in a case study.
The results of this study are also presented in Section 3. Finally, Section 4 will conclude the paper.
2. RESEARCH METHODOLOGY
According to Saaty and Vargas (2006), there are two known ways to analyze cause and effect relations:
one is the use of traditional deductive logic that is initiated with assumptions and precisely deduces
an outcome from them. The other is the holistic approach in which all the factors and criteria that
involved are laid out in advance in a hierarchy or a network system that allows for dependencies. All
possible outcomes are joined together in these structures and then both judgment and logic are used
to estimate the relative influence from which the overall answer is derived. By using this approach
in the real-world problems, we will generally reach to a sound overall outcome (Saaty and Vargas,
2006). If the decision-making elements involved in a problem are independent of each other, these
elements will be laid out in a hierarchy structure and the AHP presented by (Saaty, 1980) will be
used to solve it. In the case of dependence and interaction among the elements, a network of decision-
making elements will be formed and the ANP presented by (Saaty, 2001) will be used.
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Acts better than other methods when inconsistency increases. These methods are described in the
following sub-sections in details.
= l α , u α = (m − l ) α + l , − (u − m ) α + u
∀α ∈ 0, 1 M (1)
a ij ij ij ij ij ij ij ij
wi ≤
lij (α) ≤ u (α) (2)
ij
wj
The symbol ≤ denotes the statement “fuzzy less or equal”. In order to handle the above
inequalities easily, one can represent them as a set of single-side fuzzy constraints (3):
wi − w j uij (α) ≤
0
0; R ∈ R 2m×n
Rw ≤ (4)
Rw
1 − k Rk w ≤ dk
µk (Rk w ) = dk (5)
0 Rk w ≥ dk
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Q n −1 = {(w , …, w
1 n
|wi > 0, w1 + … + wn = 1 } (6)
Definition 1: The fuzzy feasible area P on simplex Qn-1 is a fuzzy set, described by the membership
function (7).
{ }
µp (w ) = min µ1 (R1w ), …, µm (Rm w ) | w1 + … + wn = 1
(7)
The convex fuzzy feasible area P shows the overall satisfaction of the decision-makers with a
specific crisp priority vector w. Assuming that the decision-makers are interested in the best possible
solution, it is reasonable to determine a priority vector that maximizes his overall degree of satisfaction.
Definition 2: The maximization solution is a crisp vector w* which corresponds to the maximum
fuzzy feasible area (8):
( ) { }
µp w * = min µ1 (R1w ), …, µm (Rm w ) | w1 + … + wn = 1
(8)
By introducing a new variable called λ that measures the membership degree of a given priority
vector in the feasible area P and by using (5) and (8), the problem of finding the maximizing solution
can be represented under a linear program (9):
MAX λ
s.t d k λ + Rk w ≤ dk ,
n
(9)
∑wi = 1,wi > 0,
i =1
i = 1, 2, …, n k = 1, 2, …, 2m
The optimal solution to the above problem is the (W*, λ*) vector, where W* represents the
priority vector that has a maximum degree of membership in the fuzzy feasible area and λ* shows
the maximum value for the membership degree. Meanwhile, the value of λ* measures the satisfaction
degree as a natural indicator for inconsistency of the decision-makers’ judgments and that is why it
is called the consistency index. When the human’s interval judgments are consistence, this index is
larger or equal to unit. For inconsistent judgments, the consistency index λ* takes a value between
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0 and 1 depending on the degree of inconsistency and the values of the tolerance parameters dk
(Mikhailov and Singh Madan, 2003).
3. CASE STUDY
In this study AHP, ANP, FAHP and FANP are compared with each other for the maintenance strategy
selection problem. To test the applicability of the presented research methodology, a dairy factory in
Iran was selected as the case study. For implementation of the above approach, high-risk equipment
must be identified at first. In this research, a sterile machine was selected as one of the high-risk
equipment with respect to the factory conditions and the related experts’ comments. The reason of
selecting the sterile machine is the key position it incorporates in the production line that in the case
of any failure, the production line will stop working. Therefore, the recommended approaches for
the sterile machine were executed and its results are stated in this section.
Criteria 1: The final product quality (C1): different strategies have different influences on quality
of the final product. For example, when a strategy is used for identification of the faults and
increasing the machine availability, the quality of the final product will be influenced accordingly.
Criteria 2: Efficiency (C2): the maintenance strategy efficiency can be noted from two aspects: 1)
Improvement of staff work efficiency (C21): its means using more appropriate and efficient human
resources related to the maintenance department; 2) Fault identification and reduction of failure
rate (C22): the aim of fault identification and failure reduction, involved in the condition-based
and predictive maintenance strategies, is to inform the maintenance engineers where and why a
failure occurs. As the result: the time of maintenance can be reduced and the availability of the
manufacturing system may be improved.
Criteria 3: Cost (C3): different maintenance strategies have different expenditure of hardware,
software and personnel training. The sub-criteria for criteria 3 include: 1) The hardware and
software cost (C31): for the condition-based and predictive maintenance, it is necessary to have
a number of sensors and computers. Software is needed to analyse the measured parameter data
in the condition-based and predictive strategies; 2) The production loss (C32): failure of the
more important equipment in the production line often leads to higher costs of production loss.
Selecting an appropriate maintenance strategy for such machines would reduce the production
loss; 3) The personnel training cost (C33): Only after sufficient training, the maintenance staff
can make full use of the related tools and techniques, and reach the maintenance goals.
Criteria 4: Time (C4): This criterion consists of two sub-criteria: shut-down time and maintenance
time. The sub-criteria for criteria 4 include: 1) The shutdown time (C41): the time that the
maintenance is postponed due to lack of spare parts, maintenance staff or etc. and the production
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line is thus stopped. 2) The maintenance time (C42): the required time for the maintenance activities
are different in various strategies.
Criteria 5: Availability (C5): The sub-criteria for criteria 5 include: 1) Maintain facility in good
conditions (C51): if the availability level of a machine is less than a certain limit, it is often
impossible to produce a high quality product. Different strategies will cause different availability
levels for the machines; 2) Maintain appropriate usable spare part (C52): Generally, corrective
maintenance needs more spare parts than the other maintenance strategies. The spare parts for
some machines are really expensive.
Criteria 6: Feasibility and reliability (C6): feasibility of the maintenance strategies is divided into
acceptance by the labours and the technique reliability. The sub-criteria for criteria 6 include: 1)
Technique’s reliability (C61): the condition-based and predictive maintenance strategies may be
inapplicable for some complicated production facilities; 2) Acceptance by labours (C62): managers
and maintenance staff prefer maintenance strategies that are easily implemented and understood.
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In this section, some questions are asked such as below: which of the alternatives are more important
with respect to the hardware cost sub-criteria and to what extent? It should be mentioned that both
the AHP and FAHP are modelled based on the priority vectors of importance of the evaluation
elements, while the global weights of the criteria, sub-criteria and alternatives are calculated. In order
to model the ANP and the FANP, in addition to the importance priority vectors of the elements, the
interdependence and interactions priority vectors must be calculated.
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FANP, the influence matrix of the evaluation elements was first constructed as shown in Table 3,
and the questionnaire number 2 was designed accordingly.
After that, the questionnaires number 1 and 2 were distributed among seven factory experts to
obtain their pair-wise judgments on the level of importance and influence. Determining the level
of importance and influence among the criteria and sub-criteria requires a group decision-making
approach. For this purpose, the AIP method was used to aggregate the group opinions and to determine
the priority vectors from these opinions. Therefore, the priority vectors of the individual DM were
calculated through the Mikhailov’s method first and then the arithmetic mean of these vectors were
determined. In addition, in order to simplify the calculations in the FAHP and FANP, α-cuts of the
fuzzy numbers were calculated as:
In the present study, values for α were selected as α= 0, 0.25, 0.5, 0.75 and 1. It should be noted
that the inconsistency indices for all the pair-wise comparison matrices were calculated and the DMs
were asked to revise their inconsistent comparison matrices. Followed by determination of the priority
vectors of elements’ importance, the AHP and the FAHP were run for different values of α in order
to calculate weights of the elements and then, the mean values of these weights were computed as
the final weights of criteria, sub-criteria and alternatives.
To calculate the weights of the decision elements in ANP and FANP, the priority vectors of
elements’ influence must be calculated as well as their priority vectors. In the ANP and FANP, the
vectors of importance and influence for different values of α were entered the unweighted super
matrix. For example, the unweighted super matrix for α = 0.5 in FANP is shown in Table 4. In the
next stage, the weighted super matrices were calculated and the limited super matrices were obtained
by using these super matrices. The limited super matrix in the FANP for α = 0.5 is shown in Table
5.
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Table 4. Unweighted super matrix for α = 0.5
Goal 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Criteria c1 0.2539 0 0 0 0 0 0.4365 0 0 0 0 0 0 0 0.3703 0 0 0
c2 0.1919 0.7277 0 0 0.4375 0.5962 0.2918 0.6292 0.4905 0.2914 0.3830 0 0 0 0 0 0.1413 0.4509
c3 0.0989 0.2723 0.3423 0.2075 0.2641 0.2716 0.3996 0.4761 0.1702 0 0.3182 0.4085 0 0.1641 0 0
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c4 0.1398 0 0.6351 0 0 0.1896 0 0 0.1277 0 0.6818 0.3996 0.4482 0.2333 0.1634 0.1411
c5 0.1591 0 0.2664 0.2588 0.1603 0 0 0.1813 0.1098 0.2325 0 0 0 0.1918 0.1815 0.6025 0 0
c6 0.1564 0 0.3913 0.1061 0.1946 0.1397 0 0 0 0 0.3191 0 0 0 0 0 0.6954 0.4081
Sub- c21 0 0 0.5508 0 0 0 0 0 0.5176 0.4122 0 0.1902 0.1848 0.2072 0.2914 0.3000 0
Criteria c
22
0 0 0.4492 0 0 0 0 0 0 0.3191 0 0 0.2486 0.4121 0.4028 0 0 0.2575
c31 0 0 0 0.2690 0 0 0 0.1092 0.1637 0.0000 0 0 0 0 0.1435 0.2193 0.4277 0
c32 0 0 0 0.3936 0 0 0 0.3775 0.3186 0.2687 0 0 0.1591 0.0890 0.1623 0 0 0.4461
c33 0 0 0 0.3374 0 0 0 0 0 0 0 0 0 0 0 0 0 0
c41 0 0 0 0 0.5820 0 0 0 0 0 0 0 0 0 0 0 0 0.2964
c42 0 0 0 0 0.4180 0 0 0 0 0 0 0.5836 0 0 0 0 0 0
c51 0 0 0 0 0 0.4468 0 0 0 0 0 0.2262 0 0 0 0.4807 0 0
c52 0 0 0 0 0 0.5532 0 0 0 0 0 0 0 0.2917 0 0 0.5723 0
c61 0 0 0 0 0 0 0.7256 0.1718 0 0 0 0 0 0 0 0 0
c62 0 0 0 0 0 0 0.2744 0.3415 0 0 0 0 0.4076 0 0 0 0
Table 5. Limited super matrix for α=0
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The normalized numbers of the limited super matrix were considered as the weight of element on
each row. In the ANP and FANP method, to obtain the final weights of the decision-making elements,
the mean weights of different α values were calculated. The final weights of criteria, sub-criteria,
and alternatives are shown in Tables 6-8, respectively.
Table 6 shows the final weights for the evaluation criteria with their rankings in the four mentioned
approaches. As the results show, the weights and rankings in the AHP and FAHP approaches are
similar to each other and the same similarity exists for the ANP and FANP methods. The results of
AHP and FAHP show that the greatest weight of the evaluation criteria is related to the quality of
the final product and after that the feasibility and reliability criteria are the most important, though
the time and cost criteria show the smallest weights. While in the ANP and FANP methods, the
greatest weight is associated to the efficiency and cost criteria and the smallest weight is related to
the time and quality of the final product criteria. The reason for these differences between the AHP
and FAHP with the ANP and FANP is that the methods of AHP and FAHP evaluate the criteria only
based on the level of importance and do not consider the interdependencies and interactions among
the evaluation elements. However, in most of the real-world problems, the evaluation elements have
interdependencies and interactions. For example, in the current study, the quality of the final product
is the most important criteria for the company in order to compete with the other companies and also
to reach the highest level of customer satisfaction, but this criterion in the ANP structure is the sink
node and does not affect the other criteria, yet it is still strongly influenced by the other criteria. For
example, if the maintenance cost rises, it substantially influences the product quality and leads to
a higher product quality. On the other hand, although in this problem the cost criterion in the AHP
and FAHP methods have the smallest weight, but due to its significant impact on the other criteria
(influence on all the criteria according to the influence matrix which is depicted in Figure 1), in
the ANP and FANP, this criterion is ranked in the second order. As another instance, the efficiency
criterion in the AHP and FAHP methods are ranked as being the 4th and 3rd, but this criterion is
ranked as the 1st one in the ANP and FANP methods. This matter is mainly attributed to the influence
of this criterion on the other criteria, except the cost.
Table 7 lists the sub-criteria weights and their rankings. The results of Table 7, similar to Table
6, indicate similarity of the weights and rankings in the AHP and FAHP methods and also in the ANP
and FANP methods. The results of Table 7 show that in the AHP and FAHP methods the greatest
weight is dedicated to the technique reliability, maintain appropriate usable spare part, shut-down
time and improvement of staff work efficiency sub-criteria, while in the ANP and FANP methods the
sub-criteria of improvement of the staff work efficiency, fault identification, and personnel training
cost have the greatest weights. Moreover, Table 7 shows that in the AHP and FAHP, the smallest
weights are related to the personnel training cost, production loss and hardware and software cost sub-
criteria, while in ANP and FANP, the lowest weights sub-criteria are shut-down time, maintenance
time, production loss, and maintain facility in good condition. The reason for the different rankings
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of the sub-criteria between these methods is the influence of the sub-criteria on each other and on
the criteria itself (feedback from the ANP system).
Table 8 depicts the weights and rankings of the alternatives (the maintenance strategies). It can be
observed from this table that the alternative’s rankings in all the four methods are completely similar
with only their weights being different. In addition, the obtained results show that the predictive
maintenance is the most appropriate strategy for the mentioned problem and after that; the time-based
preventive maintenance strategy has the most suitability.
4. CONCLUSION
This paper presents a comparison of ANP, AHP, FAHP and FANP in maintenance decision making.
Alternatives, including different maintenance strategies are compared using the mentioned MCDM
method, under certain and uncertain numbers, and considering different criteria. The results of this
research show that determining the local priorities of the elements requires a group process and an
individual process is not accurate enough. The proposed model is very flexible to allow the changes in
the decision elements such as inclusion of the new criteria or sub-criteria, removal of the inappropriate
criteria or sub-criteria, and changes in the pair-wise comparison judgments. In this research the
evaluation criteria and sub-criteria are dedicated to a dairy factory, while it can even be adapted or
extended for the other manufacturing environments by making the necessary modifications on the
elements such as adding a safety criterion with its related sub-criteria. At the end, it can be seen that
Maintenance Strategy AHP Rank ANP Rank FAHP Rank FANP Rank
Predictive maintenance 0.3030 1 0.2939 1 0.3275 1 0.3214 1
Preventive time-based maintenance 0.2432 3 0.2377 3 0.2354 3 0.2176 3
Preventive condition-based maintenance 0.2563 2 0.2800 2 0.2713 2 0.3067 2
Corrective maintenance 0.1976 4 0.1883 4 0.1657 4 0.1543 4
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as higher as the effectiveness of one element on the other elements is, this element will have greater
weights and therefore, the results from the ANP method is completely different from those of the
AHP. In this research, a predictive maintenance was selected as the most appropriate strategy and the
preventive strategies outperformed the corrective strategies. The results of this research is consistent
with the results of previous studies done by Nakagawa (1989), Huang, et al. (1995), Chelbi and Aı̈t-
Kadi (2001), Wang et al. (2007), Pariazar, et al. (2008), and Cheng and Tsao (2010) on the industrial
equipment. The following items were also found interesting for the future researches in this area:
Different importance weights of DMs, which can be obtained from pair-wise comparisons among
DMs, are necessary for running the aggregation of individual priorities (AIP) approach. In addition,
a sensitivity analysis can be performed for the pair-wise comparison of DMs.
ACKNOWLEDGMENT
The authors would like to thank the anonymous reviewers and the editor for their insightful comments
and suggestions. We also would like to appreciate the supports from the managers of the case company
who provide appropriate information to accomplish this research.
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Volume 7 • Issue 3 • July-September 2016
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