Renan Stenico de Campos
Universidade Metodista de Piracicaba (UNIMEP), Brazil
E-mail: renanstenico@hotmail.com
Alexandre Tadeu Simon
Universidade Metodista de Piracicaba (UNIMEP), Brazil
E-mail: alexandre.simon@unimep.br
Submission: 12/18/2018
Revision: 2/8/2019
Accept: 2/27/2019
ABSTRACT
Companies
adopt sustainable practices in order to improve the economic, environmental and
social performance of their operations. This fact does not occur with the same
intensity in maintenance operations. By adopting sustainable practices during
the implementation of maintenance strategies, there will be mitigation of
industrial maintenance impacts on sustainability. However, there are few
studies on the integration of sustainability in maintenance activities and few
companies adopt sustainable maintenance due to lack of knowledge of the subject
and its benefits. This paper aims to show how the concepts of sustainability
are being inserted in the maintenance strategies. For this purpose, a
literature review and a systematic literature review were performed. It was
verified that the concepts of sustainability are integrated into maintenance
strategies by means of sustainable criteria, with emphasis on lost production
cost, spare parts cost and expenditures associated with energy consumption and
greenhouse gas emissions (economic dimension), on pollutant emission due to
energy consumption during machining/manufacturing (environmental dimension) and
on health and safety at work (social dimension). This paper contributes to the
dissemination of the theme and motivates the companies to implement sustainable
maintenance.
Keywords: Sustainability; Maintenance Strategies;
Sustainable Maintenance
1. INTRODUCTION
Sustainability
has been used in competitive strategies of many companies to make them
different in their field. Organizations adopting sustainable practices are able
to achieve better quality in their products and services, greater market share
and increased profits (NAMBIAR, 2010). However, it should be emphasized that
sustainable practices are not limited only to achieving better economic
performance, but to integrating other performances that go beyond this perspective,
such as the environmental and social (ASHLEY, 2005).
Sustainable
manufacturing initiatives have been integrated into decision-making processes
in various industrial and government projects (O'CONNOR; SPASH, 1999).
Companies using the concept of sustainable manufacturing consider economic,
environmental and social issues at every stage of the product life cycle, from
the design to the delivery for end user (NEZAMI; YILDIRIM, 2011).
Regarding
economic issues, for example, the costs of consumed energy and generated waste
have an impact on the profitability of production systems (GUTOWSKI et al.,
2005) and reducing these costs not only results in economic benefits, but also
environmental benefits (DIMITROFF-REGATSCHNIG; SCHNITZER, 1998).
Regarding
environmental issues, the best performance is characterized by the reduction of
energy consumption, minimization of toxic waste generated, use of natural
resources efficiently and adoption of evaluation methods for the product life
cycle (PUSAVEC et al., 2010). Regarding social issues, the programs focused on
health, safety and employee qualification (JASIULEWICZ-KACZMAREK et al., 2013b)
stand out.
Although
there is an emphasis on the adoption of sustainability concepts in the design,
manufacturing, use and reuse of products (JAYAL et al., 2010), maintenance
operations are already beginning to be recognized as an essential part of the
quest for a sustainable condition (SARI et al., 2015).
Industrial
maintenance is considered a key support area for sustainable manufacturing,
contributing to the reduction of breakdowns, energy waste and internal and
external costs associated with the production line (JASIULEWICZ-KACZMAREK,
2013a; IUNG; LEVRAT, 2014). This trend can be confirmed by the emergence of the
concept of sustainable maintenance that, through maintenance strategies, seeks
a continuous improvement of maintenance actions in the economic, environmental
and social dimensions (JASIULEWICZ-KACZMAREK, 2013a; SAVINO et al., 2015).
Failure
to adopt sustainability concepts in maintenance can mean higher repair costs,
increased equipment energy consumption and increased work-related accidents
(YAN; HUA, 2010; RADHOUI et al., 2012; JASIULEWICZ-KACZMAREK et al., 2013b).
Due
to the lack of knowledge about sustainable maintenance and its benefits, very
few companies adopt the concept (FRANCIOSI et al., 2017). This can also be
confirmed by the low number of published works on the integration of
sustainability in maintenance activities (PIRES et al., 2015).
The
objective of this article is to show how sustainability concepts are being
inserted in maintenance strategies aiming to contribute to the dissemination of
the theme and motivate companies to implement sustainable maintenance.
The
article is structured in five sections, including this introduction that
presents the research objective; following are the relevant concepts and
theories; the research method adopted; the analysis and discussion of the
results obtained; and, finally, the final considerations.
2. LITERATURE REVIEW
This
section presents a literature review on sustainability, maintenance strategies
and sustainable maintenance.
2.1.
Sustainability
Sustainability
has been discussed by researchers and entrepreneurs for several years,
beginning with the discussions between 1950 and 1960 on environmental issues at
various global conferences and events, to more recent events such as the United
Nations (UN) decision to adopt a set of new sustainable development goals in
2015, also considering social and economic issues (GUDMUNDSSON et al., 2015).
Literature
presents several definitions for sustainable development, with rumors that
there are more than two hundred definitions for the term. Despite this, a
widely used concept was created in 1987 by the World Commission on Environment
and Development (WCED) and accepted by the UN at the Earth Summit in 1982,
regarded as development that meets the current needs, not compromising the
ability of future generations to meet their own needs (BRUNDTLAND, 1987).
The
definition of WCED does not distinguish sustainable development from
sustainability. Briefly, sustainable development can be described as the
process by which, over time, people achieve sustainability. Sustainability is
the goal to be achieved so that the environment presents conditions to sustain
life on Earth (PARKIN, 2000).
By
bringing the premises of sustainable development to the business environment,
organizations can be considered sustainable if they can manage their activities
and achieve good results in three dimensions that make up sustainability:
economic, environmental and social. This sustainable goal can be represented
with the concept of triple bottom line or 3P's (profit, people and planet)
formulated by John Elkington in 1998, represented in Figure 1 (ELKINGTON,
1998).
Figure 1: Concept of triple
bottom line
Source: Adapted from Elkington
(1998)
Sustainability
is integrated into production systems, considering economic, environmental and
social issues at every stage of a product's life cycle from creation to
delivery to the end user (NEZAMI; YILDIRIM, 2011). Economic issues focus on
actions that reduce production costs by managing productivity, spending, and
investments. Environmental issues focus on energy efficiency and reduction of
pollutant emissions, consumption of hazardous materials, frequency of
environmental accidents and other impacts on the environment. On the other
hand, social issues focus on to improve working conditions, health and safety
of workers and labor issues (JAMALI, 2006).
2.2.
Maintenance
Strategies
Equipment
failures can cause catastrophic effects in a production system, resulting in
higher repair costs, reduced quality of the final product, as well as causing
total shutdown of the production line. Mitigation of these effects is achieved
through an appropriate strategy for maintenance actions (SHARMA et al., 2005).
The
maintenance strategy can be described as a systematic approach (step-by-step
procedure) to keep equipment and installations in operation, involving
guidelines for investigation, identification and performance of repairs (KELLY,
1997).
The maintenance strategy
characterizes which events (including failure type, condition and periodicity)
trigger the maintenance (inspection, repair or replacement) tasks to be
performed (PINJALA, 2008). According to Marquez and Gupta (2006), maintenance
strategies are procedures used to transform business objectives into
maintenance objectives.
Most
used maintenance strategies found in literature are: i)
corrective maintenance, ii) preventive maintenance, iii) condition-based
maintenance, iv) total productive maintenance and v) reliability centered
maintenance.
Corrective
maintenance (CM) is the maintenance strategy used when there is a random
failure in a component. Generally, this strategy is implemented in companies
with large profit margins (CHITRA, 2003; WANG et al., 2007).
Preventive
maintenance (PM) is the maintenance strategy that seeks to improve the service
life of the equipment, preventing them from excessive weakening and depreciation.
This type of maintenance encompasses the activities of adjustment, repairs,
replacements, lubrication, cleaning and extension of equipment service life
(WIREMAN, 1990).
The PM makes use of the periodic inspection at
predetermined times (age or calendar time), without considering the condition
of the machine. Inadequate inspection intervals and unpredictability of
maintenance generate unnecessary costs for the company (AL-NAJJAR; ALSYOUF,
2003).
Condition-based
maintenance (CBM), also known as predictive maintenance (PdM),
is implemented by many companies today. CBM uses data collected through
vibration monitoring, ultrasonic testing, and lubrication analysis, among
others, to investigate the conditions of the elements that make up the
equipment. If the monitored value exceeds the normal level, the component is
replaced or repaired.
Generally, CBM implementation costs are high because
of the need for specialized labor force and specific equipment for monitoring.
However, the correct application and management of CBM can generate
considerable reductions in total cost of production, reducing it from 5 to 45%
(GRALL et al., 2002; AL-NAJJAR; ALSYOUF, 2003; SHARMA et al., 2005; ZHANG,
2013).
Total
productive maintenance (TPM) is a Japanese maintenance strategy that focuses on
the maximum efficiency of the production system. This maximum efficiency is
achieved through: improvement of the production system (with the reduction of
downtime and preparation of the machines, keeping the system speed constant); improving
the quality of products and services; elimination of failures due to breaks and
the constant improvement of employees' skills and knowledge (WILLMOTT; MCCARTH,
2000).
Reliability
centred maintenance (RCM) is a logical and systematic
maintenance strategy used to determine which maintenance actions should be
performed on the equipment, taking into account the operational, environmental
and safety consequences of each failure found (MOUBRAY, 2000). The success of
this strategy stems from the availability of fault data, analysis methods and
operational experience to achieve its goal (GANDHARE; AKARTE, 2012). Therefore,
one of the difficulties encountered when executing the RCM is the
unavailability of fault data in the analyzed system (SHARMA et al., 2005).
2.3.
Sustainable
Maintenance
Sustainable
maintenance emerges as a new challenge for companies using the sustainability
strategy, defined as actions or maintenance tasks that promote a balance
between the economic, environmental and social dimensions. Therefore,
sustainable maintenance does not only focus on financial terms, such as
repairing cost and materials consumed cost, but also in environmental terms -
such as greenhouse gas (GHG) emissions and energy consumption - and social
issues related to worker’s health and safety (JASIULEWICZ-KACZMAREK, 2013a).
The studies of Nezami and Yildirim
(2011), Jasiulewicz-Kaczmarek (2013b), Saniuk et al. (2015), Sari et al. (2015), Amrina and Aridharma (2016) and
Franciosi et al. (2017) also discuss the concept of sustainable maintenance,
however, superficially.
In
order for maintenance actions to promote a balance between economic,
environmental and social dimensions, sustainability concepts must first be
approached in maintenance strategies, so as to have better control of
maintenance costs, better quality of products and services, decreasing of
environmental impacts resulting from maintenance actions and contribute to the
economic well-being, health, safety and education of employees (HENNEQUIN;
RESTREPO, 2016).
In
addition to presenting the concept of sustainable maintenance, Jasiulewicz-Kaczmarek (2013a) shows the internal and
external benefits that the company acquires when practicing sustainable
maintenance. Examples of these benefits are contained in Table 1.
Table 1: Internal and external benefits when applying sustainable
maintenance
Benefits |
Economic |
Environmental |
Social |
Internal |
· Limitation of environmental charges; · Limitation of stock of materials; · Product cost per unit limit |
· Limitation of the amount of waste generated; · Limitation of energy consumption |
· Improved safety of operators and technical personnel; · Reduction of the number of
accidents at work |
External |
· Limitation of risk of serious damage; · Limitation of fines resulting
from failures; · Increasing the competitiveness
of an organization |
· Elimination or reduction of fines resulting from wrong practices; · Reduction of disturbances and
nonconformities for local societies; · Reduction in the use of
non-renewable resources |
· Positive image of the company in the context of safety and health |
Source: Jasiulewicz-Kaczmarek
(2013a)
According
to Ighravwe et al. (2017), organizations that intend
to design a sustainable maintenance plan for their facilities, with the
objective of improving maintenance actions in the manufacturing system, must
consider four decisive factors: i) selection of the
maintenance strategy, ii) training of employees involved in maintenance; iii)
control of production equipment to generate less waste; and iv) optimization of
the materials consumed during the maintenance actions, represented in Figure 2.
Figure 2: Key
factors for the implementation of sustainable maintenance
Source:
adapted from Ighravwe et al. (2017)
The
selection of the appropriate maintenance strategy minimizes the probability of
failures in the production system and its consequences related to safety,
economy and environment (KHAN; HADDARA, 2003). The training given to the
employees involved in the maintenance allows sustainable practices to be taken,
minimizing the sector's impacts on sustainability.
Control of production equipment is
essential for the reduction of environmental pollution, noise from industrial
activities, and liquids and solids generated. The optimization of the materials
consumed during maintenance actions is improved when employees are more aware
of sustainable practices (IGHRAVWE et al., 2017).
3. RESEARCH METHOD
In
order to identify and select the main works that consider the concepts of
sustainability in the maintenance strategies, the methodology of systematic
literature review of Levy and Ellis (2006) was used. The method relies on three
steps: Input, Processing and Output, as shown in Figure 3.
Figure 3: Steps
of systematic literature review
Source:
adapted from Levy and Ellis (2006)
In
Step 1, the research problem (Phase 1.1) and the objective of the work (Phase
1.2) were defined, such phases described in the introductory section of the
article. In Phase 1.3, the keywords or expressions to be used in the academic
databases were defined to find the scientific papers aligned with the study
objective (Table 2).
Table 2:
Definition of search keywords
Definition of the
keywords |
(“Sustainability”
OR “Sustainable Development” OR “Triple Bottom Line”) AND (“Maintenance” OR “Maintenance Strategy” OR “Maintenance
Management”) AND (“Industr*” OR “Compan*” OR “Machin*”) |
Source:
Authors
In
Phase 1.4, three international databases were selected to find the scientific
papers: Science Direct, Scopus and Web of Science. The databases were selected
for presenting the largest number of papers published in the area, allowing the
use of other software during the screening process and providing more details
about the selected papers.
As inclusion and exclusion criteria (Phase 1.5), only
articles published in journals and in annals of international congresses were
considered for the availability of access to the content of these documents. In
this way, 2266 articles were found in the three searched databases containing
the combinations of terms used in the title, and/or in the abstract and/or in
the keywords.
In
Step 2, the preliminary criteria defined in the previous step are processed
through six phases: know the literature (Phase 2.1), understand the literature
(Phase 2.2), apply the review (Phase 2.3), analyze the results (Phase 2.4),
compile the results (Phase 2.5) and evaluate the results (Phase 2.6); in a
cyclical way, to select the relevant papers and include other documents.
After reading the titles, abstracts and keywords, 79
articles were selected in a first screening: studies involving the concept of
sustainability and maintenance in the industrial area. The excluded articles
addressed the concepts in the field of civil construction, transportation,
agriculture, medicine and others.
After
a complete reading of the 79 articles (second screening), it was verified that
only 21 documents contemplated the insertion of the concepts of sustainability
in the maintenance strategies. Through the snowballing method, technique that
inserts relevant works cited in the references of the sample obtained by the
systematic literature review, 3 other documents were included. The small number
of articles selected shows that the subject is still little studied. The
bibliographic portfolio of selected articles is illustrated in Table 3.
In
Step 3, the presentation and discussion of the data obtained with the
systematic literature review is performed through three phases. The
bibliometric analysis (Phase 3.1) quantitatively evaluates the selected
articles from the year of publication, authors and journals that publish in the
area and methodologies applied. The content analysis (Phase 3.2) describes and
interprets the relevant information of the consulted works, in order to
understand how the concepts of sustainability are being inserted into
maintenance strategies. Phase 3.3 presents the trends, gaps and new research
opportunities in the field. The three phases are shown in the sequence.
4. ANALYSIS AND DISCUSSION OF RESULTS
This
section presents the bibliometric analysis and the content analysis of the
selected papers, as well as the discussion about trends, gaps and new research
opportunities.
4.1.
Bibliometric
Analysis
The
bibliometric analysis aims to show, through quantitative evaluations, the
number of publications that have occurred over the years, the most cited
authors, the main journals that publish the studies related to the subjects
researched and the subjects most discussed in the articles.
Table 3:
Selected articles that make up the bibliographic portfolio
Nº |
Authors |
Title |
Year of publication |
Nº of citation |
1 |
Jasiulewicz-Kaczmarek |
The role of
ergonomics in implementation of the social aspect of sustainability,
illustrated with the example of maintenance |
2013 |
19 |
2 |
Nezami and Yildirim |
A sustainability
approach for selecting maintenance strategy |
2013 |
19 |
3 |
Saniuk et al. |
Environmental favourable foundries through maintenance activities |
2015 |
13 |
4 |
Sari et al. |
Sustainable
maintenance performance measures: a pilot survey in
Malaysian automotive companies |
2015 |
13 |
5 |
Jasiulewicz-Kaczmarek |
Integrating lean and
green paradigms in maintenance management |
2014 |
13 |
6 |
Jasiulewicz-Kaczmarek |
Practical aspects of
the application of RCM to select optimal maintenance policy of the production
line |
2015 |
12 |
7 |
Yan and Hua |
Energy consumption
modeling for machine tools |
2010 |
12 |
8 |
Jasiulewicz-Kaczmarek |
The role and
contribution of maintenance in sustainable manufacturing |
2013 |
9 |
9 |
Savino et al. |
Investigating the
impact of social sustainability within maintenance operations: an action
research in heavy industry |
2015 |
6 |
10 |
Nezami and Yildirim |
A framework for a
fuzzy sustainable maintenance strategy selection problem |
2011 |
6 |
11 |
Sénéchal |
Research directions
for integrating the triple bottom line in maintenance dashboards |
2017 |
4 |
12 |
Jiang et al. |
Development and
optimization of a condition-based maintenance policy with sustainability
requirements for production system |
2018 |
2 |
13 |
Kumar et al. |
A big data driven
sustainable manufacturing framework for condition-based maintenance
prediction |
2018 |
2 |
14 |
Franciosi et al. |
Sustainable
maintenance: a periodic preventive maintenance model with sustainable spare
parts management |
2017 |
2 |
15 |
Amrina and Aridharma |
Sustainable
maintenance performance evaluation model for cement industry |
2016 |
2 |
16 |
Hoang et al. |
Investigation on the
use of energy efficiency for condition-based maintenance decision-making |
2016 |
2 |
17 |
Xia et al. |
Energy-oriented
maintenance decision-making for sustainable manufacturing based on energy
saving window |
2018 |
1 |
18 |
Radhoui et al. |
Preventive
maintenance policy for multi-component systems subject to random environmental
damage generation |
2012 |
1 |
19 |
Behzad et al. |
Improving
sustainability performance of heating facilities in a central boiler room by
condition-based maintenance |
2019 |
0 |
20 |
Do et al. |
Energy efficiency for
condition-based maintenance decision-making: application to a manufacturing
platform |
2018 |
0 |
21 |
Piechowski et al. |
Concept of the FMEA
method-based model supporting proactive and preventive maintenance activities |
2018 |
0 |
22 |
Sénéchal |
Performance
indicators nomenclatures for decision making in sustainable conditions based
maintenance |
2018 |
0 |
23 |
Macchi et al. |
Economic and
environmental impact assessment through system dynamics of
technology-enhanced maintenance services |
2016 |
0 |
24 |
Pires et al. |
Industrial
maintenance for sustainable performance: a systematic literature review |
2015 |
0 |
Source: Authors
All
24 articles with their respective year of publication and other relevant
information were cataloged according to Table 3. In Figure 4, the publications
involving the insertion of sustainability concepts in the maintenance
strategies occurred between 2010 and 2019, with more publications in 2018. It
is verified that there are few studies in this area of research, which makes it
difficult to apply the concept of sustainable maintenance in the industrial
area.
Figure 4: Number
of publications per year
Source: Authors
In
relation to the most cited authors within the selected publications, Małgorzata Jasiulewicz-Kaczmarek
is present in 5 articles; Olivier Sénéchal and Benoit Iung in 3 articles; Anh Hoang,
Farnaz G. Nezami, Marcos Macchi, Mehmet B. Yildirim and Phuc Do are authors that appeared in 2 publications; and
the other authors are present in only one publication.
Other
relevant information about the publications is related to the journals in which
they were published. In this sense, all the selected journals were quantified,
making it possible to show which journals are of major importance within the
topics researched (Table 4).
It should be noted that the journal with the largest
number of publications is the IFAC magazine, with 3 articles printed in its
database Proceedings Volumes and 3 articles contained in its database PapersOnLine. The reason for the large number of
publications is the fact that the magazine is focused on systems and controls,
with one of the pillars of publication being the maintenance field.
Table 4:
Publication number per journals
Journals |
Nº of publications |
IFAC Proceedings Volumes |
3 |
IFAC PapersOnLine |
3 |
Industrial Engineering and Engineering Management |
2 |
Journal of Cleaner Production |
2 |
International Conference on Production Research |
1 |
International Journal of Industrial and Systems
Engineering |
1 |
International Journal of Sustainable Engineering |
1 |
IOP Conference Series: Materials Science and
Engineering |
1 |
Journal of Computational Science |
1 |
Journal of Manufacturing Science and Engineering |
1 |
Journal of Quality in Maintenance Engineering |
1 |
Journal of Risk and Reliability |
1 |
Mathematical Problems in Engineering |
1 |
Metalurgija |
1 |
Occupational Safety and Hygiene |
1 |
Procedia CIRP |
1 |
Proceedings of the European Safety and Reliability
Conference |
1 |
Sustainable Systems and Technology |
1 |
Source: Authors
The
last feature analyzed was the quantification of the methodologies used in the
research. Table 5 shows that the most used methodology was the mathematical
modeling, adopted by 7 selected articles (29.0%).
Table 5:
Methodologies used at the researches
Methodology |
Number of articles |
% |
Mathematical modeling |
7 |
29.0 |
Theoretical-conceptual |
5 |
21.0 |
Survey |
5 |
21.0 |
Simulation |
4 |
16.5 |
Case study |
3 |
12.5 |
Total |
24 |
100% |
Source: Authors
4.2.
Content
Analysis
The
technique of content analysis seeks to analyze the information published by
researches in a systematic, objective and reliable way (GUTHRIE et al., 2004).
For this work, the content analysis sought to analyze how the concepts of
sustainability are being inserted in the more addressed maintenance strategies
at the literature and used in the industries.
For
CM, it is noted that selection and evaluation models involving the maintenance
strategy consider only the economic criteria, with no emphasis on environmental
and social factors. During the CM intervention, the costs associated with the
lost production, labor force and spare parts are considered, which are
classified as internal maintenance costs (RADHOUI et al., 2012; SARI et al.,
2015; FRANCIOSI et al., 2017), as well as the environmental cost of carbon
dioxide (CO2) emissions during CM, which is classified as an
external cost of maintenance (FRANCIOSI et al., 2017). According to Jiang et
al. (2018), the emphasis on the economic dimension is due to the high internal
and external costs resulting from CM compared to other maintenance strategies.
With
respect to PM, some companies are considering criteria involving the three dimensions of sustainability when selecting and evaluating this
maintenance strategy. For the economic dimension, the same internal and
external maintenance costs used to select the CM are considered (RADHOUI et
al., 2012; SARI et al., 2015; MACCHI et al., 2016; FRANCIOSI et al., 2017; JIANG
et al., 2018; XIA et al., 2018).
For the environmental
dimension, the consumption of electricity, the amount of GHG emitted and the
waste generated before and after the PM are environmental criteria employed (YAN;
HUA, 2010; NEZAMI; YILDIRAM, 2013; SANIUK et al.,
2015; JIANG et al., 2018; XIA et al., 2018). For the social dimension, the
criteria involve employee safety and health and stakeholder participation (NEZAMI;
YILDIRIM, 2013; FRANCIOSI et al., 2017).
In
the field of CBM, new optimization models are being developed with the aim of reducing the total costs of maintenance and the environmental
impacts generated. In this regard, these models evaluate the energy
consumption and CO2 emissions during the monitoring of the
equipment, as well as the influence of the costs of these ecological factors
along with other maintenance costs (HOANG et al., 2016; JIANG et al., 2018).
With
respect to TPM, all costs involved in the production system are considered
during the implementation of this maintenance strategy (NEZAMI;
YILDIRIM, 2013; PIRES
et al., 2015), in addition to the environmental and social criteria, such as:
GHG emission, energy consumption, consumption of non-renewable resources, waste
disposal (JASIULEWICZ-KACZMAREK, 2013b; JASIULEWICZ-KACZMAREK, 2014) and
ergonomic issues (JASIULEWICZ-KACZMAREK, 2013a).
According
to Saniuk et al. (2015) and Jasiulewicz-Kaczmarek
(2015), for RCM to be applied in a production system, it is necessary to make
use of a decision-making diagram to select which maintenance actions should be
performed on the equipment according to the environmental consequences,
operational and safety caused by each fault found. Therefore, it is
indispensable to use economic, environmental and social criteria during the
application of RCM.
When
analyzing the 24 selected articles with
the systematic literature review, it was noted that the concepts of
sustainability are inserted in the maintenance strategies through economic,
environmental and social indicators or criteria, which are fundamental for
decision making made by specialists. Regarding the economic criteria, the most
discussed in the studies are: cost associated with energy consumption, lost production cost, spare parts cost and cost associated
with GHG emissions.
Pollutant emission due
to energy consumption during machining/manufacturing is the most discussed
environmental criteria. For the social criteria, the most mentioned in the
publications is the health and safety at work. The full list of sustainability
criteria addressed in the publications is shown in Table 6.
Table 6:
Sustainability criteria addressed in selected publications
Dimension |
Criteria |
Authors |
Number of Articles |
Economic |
Cost associated with
energy consumption |
Hoang et al. (2016);
Do et al. (2018); Jiang et al. (2018); Xia et al.
(2018); Behzad et al. (2019) |
5 |
Lost production cost |
Radhoui et al. (2012); Nezami and Yildirim (2013);
Franciosi et al. (2017) |
3 |
|
Spare parts cost |
Radhoui et al. (2012); Nezami and Yildirim (2013);
Sari et al. (2015) |
3 |
|
Cost associated with
GHG emissions |
Macchi et al. (2016); Franciosi et al. (2017); Jiang et al.
(2018) |
3 |
|
Labor cost |
Radhoui et al. (2012); Sari
et al. (2015) |
2 |
|
Environmental |
Pollutant emission due to energy
consumption during machining/manufacturing |
Yan and Hua (2010); Nezami and Yildirim (2013); Saniuk et al. (2015); Sari et al. (2015); Amrina and Aridharma (2016); Macchi et al. (2016); Hoang
et al. (2016); Franciosi et al. (2017); Sénéchal
(2017); Do et al. (2018); Jiang et al. (2018); Sénéchal
(2018); Xia et al. (2018); Behzad et al. (2019) |
14 |
Consumption of
non-renewable resources |
Nezami and Yildirim (2013); Saniuk et al.
(2015); Sari et al. (2015); Amrina and Aridharma (2016); Sénéchal
(2017) |
5 |
|
Waste disposal |
Nezami and Yildirim (2013); Saniuk et al.
(2015); Sari et al. (2015); Sénéchal (2018) |
4 |
|
Social |
Health and safety at
work |
Nezami and Yildirim (2013); Jasiulewicz-Kaczmarek (2013b); Sari et al. (2015); Savino et al. (2015); Amrina
and Aridharma (2016); Franciosi et al. (2017); Piechowski et al. (2018) |
7 |
Stakeholder
participation |
Nezami and Yildirim (2013); Saniuk et al.
(2015); Sari et al. (2015) |
3 |
|
Noise pollution |
Saniuk et al. (2015); Sari et al. (2015) |
2 |
Source: Authors
4.3.
Trends,
Gaps and New Research Opportunities
It
was noted that the lack of studies and application of the concepts of
sustainability by the industrial managers along with the maintenance strategies
was due to the presumption that the reduction of environmental and social
impacts increase the costs of maintenance actions, as mentioned by Nezami and Yildiran (2013).
However,
in the last few years, some articles have been deepened in the assumption
raised and noted that the inclusion of the sustainability criteria in the
maintenance actions helps: in the optimization of the preventive stops, in the
control of the use of raw material during the production, in the control of
consumption of electricity and of lubricating oil by the equipment and
reduction of the impacts in the sustainability. By way of example, Franciosi et
al. (2017) noted that food companies considering the environmental and social
costs during PM planning achieved a reduction of up to 5% in total maintenance
costs.
In addition, Saniuk et al. (2015), through in-depth research with
companies in the foundry field that use sustainable criteria in the maintenance
area, obtained: 20% savings in the use of raw material during production, 15%
reduction in the consumption of electricity by equipment, 20% longer service
life of lubricating oils and reduction of noise and emissions of pollutants by
the machines.
The
use of methods or tools enabling successful management of the maintenance
strategies can be crucial for the maintenance actions efficiency and mitigation
of their sustainability impacts. This case can be exemplified through the use
of Failure Mode and Effect Analysis (FMEA) method in PM. According to Piechowski et al. (2018), this combination reduces or
eliminates the causes of failures, taking into account the effects of failures
on safety of operators and process as well as threats to the environment.
Others
researches are developing methods that use sustainability criteria to achieve
maximum productive capacity and equipment availability at the lowest possible
cost, with emphasis on productive systems that adopt PM or CBM (YAN;
HUA, 2010; RADHOUI et al., 2012; SANIUK et al., 2015;
HOANG et al., 2016; FRANCIOSI et al., 2017; JIANG et al., 2018).
Currently,
CBM is being used more frequently by companies to minimize economic losses by
unexpected interruptions of equipment, reduce energy consumption during
production and provide a safe working environment for employees. These benefits
are verified by Do et al. (2018) through a case study on the TELMA platform,
software dedicated to the electronic maintenance of a real industry, and by Behzad et al. (2019) through the use of CBM in a central
boiler room, revealing a saving of 591312 kWh in gas consumption and 151795
liters in water consumption, which equals a saving of 2330 US dollars in
resource consumption and 35400 US dollars in maintenance cost.
In
order to make condition monitoring and prediction information more precise and,
consequently, to achieve a more sustainable system, the use of Cyber Physical
Systems and Big Data (Industry 4.0 technologies) has been used with CBM.
According to Sénéchal (2018) and Kumar et al. (2018),
Industry 4.0 tools are important for the acquisition and management of data
obtained during maintenance actions and for the formation of sustainability
indicators.
Most
methods developed use data from the literature to quantify the environmental
and social impacts resulting from the evaluated maintenance actions, generating
doubts as to whether the impacts evaluated are in line with the actual
situation of the cases studied.
Another
identified gap concerns the difficulty in evaluating the social impacts
resulting from maintenance actions and, consequently, using social data as an
aid in the planning of maintenance strategies in a company. According to
Franciosi et al. (2017), costs incurred for the health, safety and well-being
of employees and society interfere with the total cost of maintenance.
Given
the gaps presented, future research may:
·
Develop methods that use technological
tools to collect and store data on the environmental and social impacts of
industrial maintenance in the evaluated companies, such as the electronic
platforms TELMA, PROTEUS and CASIP, and the technologies of Industry 4.0, such
as Big Data, Internet of Things and Cyber Physical Systems;
·
Conduct case studies that quantitatively
establish the importance of considering social criteria during the planning of
maintenance strategies.
5. FINAL CONSIDERATIONS
Maintenance
has long been recognized as an activity
responsible for optimizing the availability of equipment at the lowest possible
cost. From a strategic perspective, maintenance also has the responsibility to
reduce environmental impacts and help social well-being. However, few companies
adopt the sustainable maintenance because they ignore the subject and its
benefits. In addition, there are few articles on integrating sustainability
into maintenance activities, which contributes to its lack of dissemination.
This article aimed to show how sustainability concepts are being inserted in
the maintenance strategies aiming to contribute to the dissemination of the
theme and motivate the companies to implement sustainable maintenance.
In
order to reach the objective, a systematic literature review was carried out
and twenty-four most representative publications on the subject were identified.
The bibliometric analysis showed that the publications involving the insertion
of sustainability concepts in the maintenance strategies occurred between 2010
and 2019, with more publications in 2018.
The
research found that sustainability concepts are integrated into maintenance
strategies through economic, environmental and social criteria, which are fundamental for decision making made by
specialists. As for the economic criteria, the most discussed in the
studies are: cost associated with energy consumption,
lost production cost, spare parts cost and cost associated with GHG emissions.
For the environmental criteria, the most discussed in the selected publications
is the pollutant emission due to energy consumption during
machining/manufacturing. Regarding the social criteria, the health and safety
at work is the most approached.
The study also identified that there is a trend in the
development of methods using sustainability criteria to achieve maximum productive capacity and equipment
availability at the lowest possible cost, with emphasis on productive systems
that adopt PM or CBM. However, most methods developed do not use data on the
impacts of industrial maintenance on sustainability to plan the maintenance
strategies and also do not emphasize the social impacts. Based on these
assumptions, the authors suggest the development of new methods that fill these
identified gaps, using technological tools to collect and store data the
sustainability impacts of maintenance, such as the electronic platforms TELMA,
PROTEUS and CASIP, and the technologies of Industry 4.0, such as Big Data,
Internet of Things and Cyber Physical Systems.
The
results and conclusions presented are limited to the selected databases
(Science Direct, Scopus and Web of Science), and it is necessary to extend the
current research through other bases. However, although there is a limitation,
the findings presented in this article contribute to
the development of the field of knowledge and can serve as inspiration for the
development of new studies, both for academics and professionals in the
maintenance and sustainability areas of the industry.
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