Integrated Maintenance Strategies in a Hybrid Manufacturing-Remanufacturing Environment Under Operational Deterioration and Learning Effect

The present paper investigates the integration of production and operation-based maintenance planning within an imperfect manufacturing-remanufacturing framework. The considered system undergoes gradual deterioration and is affected by learning effects, impacting its reliability and product quality. To face this deterioration, we propose a maintenance strategy involving minimal corrective maintenance upon failure, imperfect preventive maintenance that brings the machine back to a condition between “As Bad As Old” and “As Good As New,” and overhaul when defect levels reach a specified threshold to restore the system to its original condition. We propose a mixed-integer nonlinear programming model to optimize integrated manufacturing, remanufacturing, and maintenance plan, intending to minimize all costs, including those associated with manufacturing, remanufacturing, holding, and maintenance. Computational experiments are conducted to discuss the managerial insights gained from the developed strategy.