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A large number of research articles have appeared in the literature during the last two decades on the subject of system reliability optimisation, each with a view to providing simple, exact and efficient techniques. Here, an efficient, fast and exact technique is proposed for solving integer‐programming problems that normally arise in optimal reliability design problems. The algorithm presented is superior to any of the earlier methods available so far, being based on functional evaluations and a limited systematic search close to the boundary of resources. Thus it can quickly solve even very large system problems. It can also be effectively used with other operations research problems involving integer‐programming formulations.

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