A Budget-Sensitive Approach to Scheduling Maintenance in a Total Productive Maintenance (TPM) Program


Scheduling planned maintenance activities is key to the success of Total Productive Maintenance (TPM) in reducing the mean and variability of production lead time. Most existing maintenance-scheduling models are risk-neutral, striving to control long-run costs. Some are variance-penalizing, addressing both average cost and cost variance. Neither addresses budget constraints. We present two models that use semi-variance combined with the mean to simultaneously optimize maintenance with respect to long-run costs and short-term budgets. The first model, geared for individual pieces of equipment (e.g., a pump or dryer), uses renewal theory. The second model presented is based on Markov decision processes and is appropriate for manufacturing systems composed of several units, any one of which can fail. An application of each model is presented. Beneficial operational costs variance is not penalized in this approach, which is more appropriate.


Engineering Management and Systems Engineering

Second Department

Psychological Science

Keywords and Phrases

Average cost; Budget constraint; Cost variance; Leadtime; Markov Decision Processes; Operational costs; Planned maintenance; Preventative maintenance; Renewal theory; Semivariances; Total productive maintenance; Budget control; Costs; Dryers (equipment); Markov processes; Scheduling; Maintenance; Budget-based scheduling; Preventative maintenance scheduling; Semivariance

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Article - Journal

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