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In this paper, we propose a hybrid method to evaluate reliability of large and complex networks that incorporates the best features of earlier techniques such as KDH88 and CAREL. The present method combines CAREL’s COMpare and REDuce operators along with KDH88 and eliminates the use of the other two operators of CAREL, thus resulting in an extensive reduction in the number of exclusive and mutually disjoint terms. The procedure not only saves CPU time by an appreciable amount but also can be run even on a low‐end PC. To demonstrate the advantage of handling a large complex system on a relatively small computer, we provide a comparison of the present approach with CAREL and KDH88 and solve several problems of various complexities on a low‐end PC.

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.