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The cost of maintenance in industrial facilities has been estimated as 15-40% (an average of 28%) of total production costs (Mobley, 1990; Sheu and Kra-jewski, 1994). The amount of money that companies spent yearly on mainte-nance can be as large as the net income earned (McKone and Wiess, 1998). Modern manufacturing systems generally consist of automated and flexible machines, which operate at much higher rates than the traditional or conven-tional machines. While the traditional machining systems operate at as low as 20% utilization rates, automated and Flexible Manufacturing Systems (FMS) can operate at 70-80% utilization rates (Vineyard and Meredith, 1992). As a re-sult of this higher utilization rates, automated manufacturing systems may in-cur four times more wear and tear than traditional manufacturing systems. The effect of such an accelerated usage on system performance is not well studied. However, the accelerated usage of an automated system would result in higher failure rates, which in turn would increase the importance of main-tenance and maintenance-related activities as well as effective maintenance management. While maintenance actions can reduce the effects of breakdowns due to wear-outs, random failures are still unavoidable. Therefore, it is impor-tant to understand the implications of a given maintenance plan on a system before the implementation of such a plan. Modern manufacturing systems are built according to the volume/variety ratio of production. A facility may be constructed either for high variety of prod-ucts, each with low volume of production, or for a special product with high volume of production. In the first case, flexible machines are utilized in a job shop environment to produce a variety of products, while in the second case special purpose machinery are serially linked to form transfer lines for high production rates and volumes. In any case, the importance of maintenance function has increased due to its role in keeping and improving the equipment

Maintenance Management and Modeling in Modern Manufacturing Systems