Simulation platform for anticipative plant-level maintenance decision support system

Global competition and increasing customer expectations are forcing automobile manufacturers to improve their operations. Maintenance, being one of the most critical components in many industries, has a direct impact on the improvement of the overall production performance. In this paper, we introduce an anticipative plant-level maintenance decision support system (APMDSS) that provides guidance on corrective and preventive maintenance priorities based on the equipment bottleneck ranks with the objective of improving daily plant throughput. APMDSS anticipates the plant dynamics (i.e. bottlenecks, hourly buffer levels and likelihood of machine breakdowns) for upcoming shifts using starting state information of the production shift (e.g. equipment maintenance history, operational status of machines, buffer levels and scheduled production model mix). We also evaluate the performance of APMDSS using real data from an automotive body shop experiencing routine throughput difficulties due to frequent machine breakdowns. The results are compared with other methods from the literature and found to be superior in many settings.