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.

Research focused on integration of machine operators with information flow in manufacturing process according to Industry 4.0 requirements are presented in this paper. A special IT system connecting together machine operators, machine control, process and machine monitoring with companywide IT systems is developed. It is an answer on manufacture of airplane industry requirements. The main aim of the system presented in the article is full automation of information flow between a management level represented by Integrated Management IT System and manufacturing process level. From the management level an information about particular orders are taken, back an on-line information about manufacturing process and manufactured parts are given. System allows automatic identification of tasks for machine operator and particular currently machined part. Operator can verify information about process and tasks. System allows on-line analyzing process data. It is based on information from machining acquired: machine operator, process and machine monitoring systems and measurement devices handled by operator. Process data is integrated with related order as a history of particular manufactured part. System allows for measurement data analysis based on Statistical Process Control algorithm dedicated for short batches. It supports operator in process control. Measurement data are integrated with order data as a part of history of manufactured product. Finally a conception of Cyber-Physical Systems applying in integrated Shop Floor Control and Monitoring systems is presented and discussed.