Determining maintenance system requirements by viewpoint of reliability and lean thinking: a MODM approach

Purpose ‐ The purpose of this paper is to formulate a model which not only determines minimum level of maintenance requirements but also satisfies expected reliability level. Design/methodology/approach ‐ A multi-objective decision making (MODM) model has been developed by viewpoint of decreasing wastes and increasing system reliability. Wastes that have been minimized are maintenance requirements (i.e. labor, spare parts, reserve system and productive maintenance activities) and maintenance system reliability that has been maximized is a function of maintenance requirements. This paper proposed goal programming model for decision-making aid and a real case in an existing Iranian automobile manufacturing company was studied. Findings ‐ Output of the proposed model was optimum level of maintenance requirements which satisfies the expected reliability level. For example, outputs of model for man hour approximately are the same as available maximum level and inspection, service and test and adjustment activities are not necessary 12 times a year for all the machineries. Practical implications ‐ This model is useful for managers because they could use that in any maintenance systems and it would ensure them in achieving minimum level of maintenance requirements and the expected reliability level. Originality/value ‐ Since lean concept has appeared, many works have been done on decreasing or even eliminating of waste such as extra inventory. Although these studies have not taken into account expected reliability seriously, this paper considers these two issues together.