A Green Manufacturing Model: Joint Optimization of Maintenance, Scheduling, and Sustainability
Abstract
This study proposes an integrated framework for sustainable manufacturing that jointly optimizes production scheduling, maintenance planning, and carbon-conscious energy management. A Mixed-Integer Nonlinear Programming (MINLP) model is developed to minimize makespan while maintaining machine reliability and ensuring compliance with greenhouse gas (GHG) emission limits. The model incorporates speed scaling as a decision variable, capturing the trade-off between processing time, energy consumption, and machine degradation. Preventive maintenance (PM) and minimal repair (MR) strategies are explicitly modeled using a Weibull-based failure distribution, and a carbon cap constraint is introduced to bound total emissions. A case study demonstrates the model's practical relevance, and scenario-based sensitivity analysis reveals key managerial insights. For example, excluding PM increases the makespan by over 21.80% and emissions by 5%, while relying solely on PM raises total maintenance time by more than 75%. These findings highlight the importance of balancing maintenance strategies and speed decisions to achieve both operational and environmental objectives. © 2025 Computers and Industrial Engineering. All rights reserved.