The relationship between preventive maintenance and manufacturing system performance

A common lament of the preventive maintenance (PM) crusaders is that production supervisors are often unwilling to lose valuable machine time when there are jobs waiting to be processed and do not assign high enough priority to PM. Maintenance activities that depend dynamically on system state are too complicated to implement and their overall impact on system performance, measured in terms of average tardiness or work-in-process (WIP) inventory, is difficult to predict. In this article, we present some easy to implement state-dependent PM policies that are consistent with the realities of production environment. We also develop polling models based analyses that could be used to obtain system performance metrics when such policies are implemented. We show that there are situations in which increased PM activity can lower total expected WIP (and overall tardiness) on its own, i.e., without accounting for the lower unplanned downtime. We also include examples that explain the interaction between duration of PM activity and switchover times. We identify cases in which a simple state-independent PM policy outperforms the more sophisticated state-dependent policies.