Maintenance Activities Planning by Integrating Computer Simulation and Data Envelopment Analysis

Document Type : Research Paper


School of Industrial Engineering, College of Engineering, University of Tehran, Tehran, Iran


Many serious accidents have happened in the world, in which systems have been large-scale and complex, and caused heavy damage and a social sense of instability. Furthermore, advanced nations have almost finished public infrastructure and rushed into a maintenance period. Since maintenance is more important than production and construction, then more maintenance for environmental considerations and protection of natural resources is required. So, in the past four decades, valuable contributions to maintenance policies in the reliability theory have been made. In this paper, a maintenance planning problem is considered. First, maintenance activities are simulated via Awesim. Production and maintenance functions are estimated using historical data. Then simulation is carried out for different scenarios which are combinations of periodic maintenance, and outputs are computed. Since the problem is multi-criteria decision making, a data envelopment analysis (DEA) method is used to select the preferred policy. Finally the preferred alternative is selected to optimize the cost, reliability, availability, queue length and machine utilization.


  1. Nakagawa, T. (2005) "Maintenance theory of reliability." Springer Series in Reliability Engineering.
  2. Marquez, A.C. and Gupta, J.N.D. (2006) “Contemporary maintenance management: process, framework and supporting pillars.” Omega, Vol. 34, PP. 313-326.
  3. Martin, H.H. (1997) “Contracting out maintenance and a plan for future research.” Journal of Quality in Maintenance Engineering, Vol. 3 No. 2, PP. 81-90.
  4. Ulusoy, G., Or, I. and Soydan, N. (1992) “Design and implementation of a maintenance planning and control system.” International Journal of Production Economics, Vol. 24, PP. 263-272.
  5. Ashayeri, J. (2007) “Development of computer-aided maintenance resources planning (CAMRP): A case of multiple CNC machining centers.” Robotics and Computer-Integrated Manufacturing, Vol. 23, PP. 614–623.
  6. Quéré, Y. L., Sevaux, M., Tahon, C and Trentesaux, D. (2003) “Reactive Scheduling of Complex System Maintenance in a Cooperative Environment With Communication Times.” IEEE TRANSACTIONS ON SYSTEMS, MAN, AND CYBERNETICS—PART C: APPLICATIONS AND REVIEWS, Vol. 33, No. 2, PP. 225-234.
  7. Ashayeri, J., Teelen, A. and Selen, W. (1996) “A production and maintenance planning model for the process industry.” International Journal of Production Research, Vol. 34, PP. 3311-3326.
  8. Haghani, A. and Shafahi, Y. (2002) “Bus maintenance systems and maintenance scheduling: model formulations and solutions.” Transportation Research Part A, Vol. 36, PP. 453–482.
  9. Ok, S.Y., Lee, S.Y. and Park, W. (2013) “Robust multi-objective maintenance planning of deteriorating bridges against uncertainty in performance model.” Advances in Engineering Software, Vol. 65, PP. 32–42.
  10. Cassady, C. R. and Kutanoglu, E. (2005) “Integrating Preventive Maintenance Planning and Production Scheduling for a Single Machine.” IEEE Transactions on Reliability, Vol. 54, No. 2, PP. 304-309.
  11. Worm, J. M. and Harten, A. V. (1996) “Model based decision support for planning of road maintenance.” Reliability Engineering and System Safety, Vol. 51, PP. 305-316.
  12. Mijailovic, V. (2003) “Probabilistic method for planning of maintenance activities of substation components.” Electric Power Systems Research, Vol. 64, PP. 53-58.
  13. Higgins, A. (1998) “Scheduling of Railway Track Maintenance Activities and Crews.” The Journal of the Operational Research Society, Vol. 49, No. 10, PP. 1026-1033.
  14. Chen, T., Li, J., Jin, P. and Cai, G. (2013) “Reusable rocket engine preventive maintenance scheduling using genetic algorithm.” Reliability Engineering and System Safety, Vol.114, PP. 52–60.
  15. Zheng, Y., Chen, S. and Ling, H. (2013) “Efficient multi-objective tabu search for emergency equipment maintenance scheduling in disaster rescue.” Optim Lett, Vol. 7, PP. 89–100.
  16. Hadavi, S.M.H. (2008) “Risk-Based, genetic algorithm approach to optimize outage maintenance schedule.” Annals of Nuclear Energy, Vol. 35, PP. 601–609.
  17. Rezg, N., Xie, X. and Mati, Y. (2004) “Joint optimization of preventive maintenance and inventory control in a production line using simulation.” International Journal of Production Research, Vol. 42, No. 10, PP. 2029–2046.
  18.  Rezg, N., Chelbi, A. and Xie, X. (2005) “Modeling and optimizing a joint inventory control and preventive maintenance strategy for a randomly failing production unit: analytical and simulation approaches.” Int. J. Computer Integrated Manufacturing, Vol. 18, No. 2–3, PP. 225 – 235.
  19.  Roux, O., Jamali, M. A., Kadi, D. A and Chatelet, E. (2008) “Development of simulation and optimization platform to analyse maintenance policies performances for manufacturing systems.” International Journal of Computer Integrated Manufacturing, Vol. 21, No. 4, PP. 407-414.
  20. Sarker, R. and Haque, A. (2000) “Optimization of maintenance and spare provisioning policy using simulation.” Applied Mathematical Modelling, Vol. 24, PP. 751-760.
  21. Mjema, E.A.M. (2002) “An analysis of personnel capacity requirement in the maintenance department by using a simulation method.” Journal of Quality Maintenance Engineering, Vol. 8, No. 3, PP. 253-273.
  22. Langer, R., Lia, J., Biller, S., Chang, Q., Huang, N. and Xiao, G. (2010) “Simulation study of a bottleneck-based dispatching policy for a maintenance workforce.” International Journal of Production Research, Vol. 48, No. 6, PP. 1745–1763.
  23. White, E.S.W. (1998) “System modeling and simulation for predictive maintenance.” Cybernetics and Systems, Vol. 29, No. 5, PP. 481-498.
  24. Yoo, J. and Garcia-Diaz, A. (2008) “Cost-effective selection and multi-period scheduling of pavement maintenance and rehabilitation strategies.” Engineering Optimization, Vol. 40, No. 3, PP. 205–222.
  25. Goel, A. and Meisel, F. (2013) “Workforce routing and scheduling for electricity network maintenance with downtime minimization.” European Journal of Operational Research, Vol. 231, No. 1, PP. 210–228.
  26. Ali, A.I. and Lerme, C.S. (1997) “Comparative advantage and disadvantage in DEA.” Annals of Operations Research , Vol. 73, Issue 0, PP. 215-232.
  27. Bilinton, R. and Allan, R.N. (1992) “Reliability Evaluation of Engineering Systems: Concepts and Techniques.” Springer US.
  28. Charnes, A., Cooper, W.W. and Rhodes, E. (1978) “Measuring the efficiency of decision making units.” European Journal of Operational Research, Vol. 2, No. 6, PP. 429-444.