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Towards strategic development of maintenance and its effects on production performance by using system dynamics in the automotive industry
University of Skövde, School of Engineering Science. University of Skövde, The Virtual Systems Research Centre. (Production and Automation Engineering, Produktion och automatiseringsteknik)ORCID iD: 0000-0001-8188-7288
University of Skövde, School of Engineering Science. University of Skövde, The Virtual Systems Research Centre. (Production and Automation Engineering, Produktion och automatiseringsteknik)ORCID iD: 0000-0003-0111-1776
University of Skövde, School of Engineering Science. University of Skövde, The Virtual Systems Research Centre. (Production and Automation Engineering, Produktion och automatiseringsteknik)ORCID iD: 0000-0002-0880-2572
2018 (English)In: International Journal of Production Economics, ISSN 0925-5273, E-ISSN 1873-7579, Vol. 200, p. 151-169Article in journal (Refereed) Published
Abstract [en]

Managing maintenance within an economical short-termism framework, without considering the consequential long-term cost effect, is very common in industry. This research presents a novel conceptual system dynamics model for the study of the dynamic behaviors of maintenance performance and costs, which aims to illuminate insights for the support of the long-term, strategic development of manufacturing maintenance. By novel, we claim the model promotes a system's view of maintenance costs that include its dynamic consequential costs as the combined result of several interacting maintenance levels throughout the constituent feedback structures. These range from the applied combination of maintenance methodologies to the resulting proactiveness in production, which is based on the rate of continuous improvements arising from the root cause analyses of breakdowns. The purpose of using system dynamics is to support the investigations of the causal relationships between strategic initiatives and performance results, and to enable analyses that take into consideration the time delays between different actions, in order to support the sound formulation of policies to develop maintenance and production performances. The model construction and validation process has been supported by two large maintenance organizations operating in the Swedish automotive industry. Experimental results show that intended changes can have both short and long-term consequences, and that obvious and hidden dynamic behavioral effects, which have not been reported in the literature previously, may be in the system. We believe the model can help to illuminate the holistic value of maintenance on the one hand and support its strategic development as well as the organizational transformation into proactiveness on the other.

Place, publisher, year, edition, pages
2018. Vol. 200, p. 151-169
Keyword [en]
Maintenance performance, Strategic development, System dynamics, Simulation
National Category
Engineering and Technology Reliability and Maintenance Other Mechanical Engineering Mechanical Engineering
Research subject
INF201 Virtual Production Development; Production and Automation Engineering
Identifiers
URN: urn:nbn:se:his:diva-15002DOI: 10.1016/j.ijpe.2018.03.024OAI: oai:DiVA.org:his-15002DiVA, id: diva2:1194592
Projects
IPSI
Available from: 2018-04-03 Created: 2018-04-03 Last updated: 2018-04-13Bibliographically approved
In thesis
1. Towards strategic development of maintenance and its effects on production performance: A hybrid simulation-based optimization framework
Open this publication in new window or tab >>Towards strategic development of maintenance and its effects on production performance: A hybrid simulation-based optimization framework
2018 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Managing maintenance in manufacturing within an economical short-termism framework and taking the consequential long-term cost effects into account is hard. The increasing complexity of managing maintenance and its impact on the business results calls for more advanced methods to support long-term development through effective activities in the production system environment. This problem-based design science research has evolved into the novel concept of a hybrid simulation-based optimization (SBO) framework which integrates multi-objective optimization (MOO) with system dynamics (SD) and discrete-event simulation (DES) respectively. The objective is to support managers in their decision-making on the strategic and operational levels for prioritizing activities to develop maintenance and production performance.

To exemplify the hybrid SBO framework this research presents an SD model for the study of the dynamic behaviors of maintenance performance and costs, which aims to illuminate insights for the support of the long-term strategic development of maintenance practices. The model promotes a system view of maintenance costs that includes the dynamic consequential costs as the combined result of several interacting maintenance levels throughout the constituent feedback structures. These levels range from the applied combination of maintenance methodologies to the resulting proactiveness in production, such as the ratio between planned and unplanned downtime, in continuous change based on the rate of improvements arising from root-cause analyses of breakdowns. The model creation and validation process have been supported by two large maintenance organizations operating in the Swedish automotive industry. Experimental results show that intended changes can have both short-term and longterm consequences, and that the system may show both obvious and hidden dynamic behavioral effects.

The application of MOO distinguishes this work from previous research efforts that have mixed SD and DES. It presents a unique methodology to support more quantitative and objective-driven decision making in maintenance management, in which the outcome of an SD+MOO strategy selection process forms the basis for performance improvements on the operations level. This is achieved by framing the potential gains in operations in the DES+MOO study, as a result of the applied strategy in the SD model. All in all, this hybrid SBO framework allows pinpointing maintenance activities based on the analysis of the feedback behavior that generates less reactive load on the maintenance organization.

Place, publisher, year, edition, pages
Skövde: University of Skövde, 2018. p. 226
Series
Dissertation Series ; 21
Keyword
Strategic development, maintenance behavior, maintenance management, sustainable change, tradeoff optimization, system dynamics, discrete event simulation, problem structuring, multi-objective optimization, decision support
National Category
Reliability and Maintenance Production Engineering, Human Work Science and Ergonomics
Research subject
Production and Automation Engineering
Identifiers
urn:nbn:se:his:diva-15036 (URN)978-91-984187-3-6 (ISBN)
Public defence
2018-04-23, Insikten, Kanikegränd 3A, Skövde, 13:15 (English)
Opponent
Supervisors
Projects
IPSI Research School
Available from: 2018-04-16 Created: 2018-04-12 Last updated: 2018-04-16Bibliographically approved

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Linnéusson, GaryNg, Amos H. C.Aslam, Tehseen

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