Maturity level of predictive maintenance application in small and medium-sized industries: Case of Morocco

In order to remain competitive in the long term and to push the company's efficiency to its limits, entrepreneurs are more and more open to the idea of integrating into Industry 4.0 aiming mainly at filling the important downtimes and the associated productivity losses by implementing predictive maintenance. This concept, common in developed countries, is much less widespread in Morocco and even less in small and medium-sized Moroccan companies. The objective of this article is to study the maturity level of predictive maintenance in Moroccan small and medium-sized enterprises, through a questionnaire validated by experts and made available to several companies. Valid data from 115 companies throughout the kingdom operating in different sectors were collected and processed by descriptive and factorial analysis under SPSS software. The results obtained show that only 33% of our sample were able to implement predictive maintenance, and that the expected benefits of this approach are the minimization of downtime at 96.5% and the increase in productivity at 94.8%, The main challenges observed are the lack of team motivation and a corporate culture unsuited to digitalization, which represents 42.277% of the total variance, lack of financial resources at 12.916% of the total variance and lack of data protection at 11.644% of the total variance. This analysis indicates that the level of maturity regarding the application of predictive maintenance in Moroccan small and medium-sized companies is low, these rates can be used to improve the root causes

Lean integration in maintenance logistics management: a new sustainable framework

The current industrial constraints on production systems, especially availability problems are complicating maintenance managers’ mission and making longer and further performance improvement process. Dealing with these problems in a wiser managerial vision respecting sustainability dimensions would be more efficient to optimize all resources. In this paper, and after addressing the lean/sustainability challenge in a the literature to define main research orientations and critical points in manufacturing and then maintenance specific context, two case studies have been conducted in two production systems in Morocco and Canada, within the objective to set a clearer scene of the lean philosophy implementation in maintenance and within the sustainability scope from an empirical perspective. To activate the social dimension being often non-integrated in the lean/sustainability initiatives, the article authors reveal an original research direction assigning maintenance logistics as the leading part of our approach to cover all sustainability dimensions. Furthermore, its management is discussed for the first time in a sustainable framework, where the authors propose a new model considering the lean/sustainable perspective and inspired by the rich Human-Machine interaction memory to solve daily maintenance problems exploiting the operators’ experience feedback

Integrated Production and Logistics Planning

Industrial planning systems have undergone considerable evolution in recent decades, starting from MRP, then ERP, and finally advanced planning and scheduling systems (APS). This evolution took place by dint of the evolution of information and communication technologies, and also due to industrial stakeholder integration tendency forming global supply chains in order to optimize costs and lead times. The purpose of this article is to present a new integrated short and medium term planning approach for upstream logistics (necessary for procurement) and production, this new approach is the MLRP "Manufacturing and Logistic Requirement Planning ". We introduce in this paper a new bill of materials structure that is adapted to the MLRP, and then we present the proposed algorithm which allows determining production and logistics needs for all bills of materials components. Finally, we present the proposed information system that implements the MLRP.</p

Integrated Production and Logistics Planning

Industrial planning systems have undergone considerable evolution in recent decades, starting from MRP, then ERP, and finally advanced planning and scheduling systems (APS). This evolution took place by dint of the evolution of information and communication technologies, and also due to industrial stakeholder integration tendency forming global supply chains in order to optimize costs and lead times. The purpose of this article is to present a new integrated short and medium term planning approach for upstream logistics (necessary for procurement) and production, this new approach is the MLRP "Manufacturing and Logistic Requirement Planning ". We introduce in this paper a new bill of materials structure that is adapted to the MLRP, and then we present the proposed algorithm which allows determining production and logistics needs for all bills of materials components. Finally, we present the proposed information system that implements the MLRP

Digital Twin Based SUDIHA Architecture to Smart Shopfloor Scheduling

Standing on the brink of the fourth industrial revolution, Cyber Physical Systems (CPS) are considered the basic components of the Smart Factory. One important challenge in cyber physical production systems is dynamic scheduling that can handle random disruptions such as failures, raw material shortages and quality defects. To achieve dynamic scheduling, we have proposed a Supervised and Distributed Holonic architecture we called SUDIHA. This architecture incorporates three Holons: Product Holon, Resource Holon and Order Holon and combines global supervision, achieved by Product Holon, with dynamic local control, achieved by Resource Holon. The Digital Twin (DT) concept is generally used to design CPS; it is virtual copies of the system that can interact with the physical counterparts in a bi-directional way. It seems to be promising to tackle the complexity and increase manufacturing system flexibility. In this paper, we use a DT Model to improve the SUDIHA architecture. We propose a Digital Twin based SUDIHA architecture (DT-SUDIHA). The paper will describe Digital Twins’ configuration of each Holon of the SUDIHA Architecture, and the intelligent and real time data driven operation control of this architecture. A case study is carried out at the ENSAM-Meknes flexible workshop to prove the effectiveness of the proposed approach

An Intelligent Method for the Scheduling of Cyber Physical Production Systems

The new industrial era, industry 4.0, leans on Cyber Physical Systems CPS. It is an emergent approach of Production System design that consists of the intimate integration between physical processes and information computation and communication systems. The CPSs redefine the decision-making process in shop floor level to reach an intelligent shop floor control. The scheduling is one of the most important shop floor control functions. In this paper, we propose a cooperative scheduling based on multi-agents modelling for Cyber Physical Production Systems. To validate this approach, we describe a use case in which we implement a scheduling module within a flexible machining cell control tool