journal article·2021-07-28Open access

Innovative Approach to Preventive Maintenance of Production Equipment Based on a Modified TPM Methodology for Industry 4.0

Filip Hardt, Martin Kotyrba, Eva Volna, Robert Jarusek

Applied Sciences· Volume 11· Issue 15

Abstract

Preventive maintenance (PM) in the production industry is one of the most essential measures to eliminate accidental machinery failures by replacing/repairing worn out machines or parts. The decision of when and where to perform preventive maintenance is non-trivial due to the complex and stochastic nature of the industry where PM is implemented. This article deals with the theoretical and practical implementation of preventive maintenance based on a unique modification of the total productive maintenance (TPM) methodology. The innovative approach of preventive maintenance management was implemented in the real production hall of ITT (Czech Republic) and has been verified. Within preventive maintenance, the new concept brings in an innovative method of managing the maintenance process as a whole, from abstract methodical conception to practical usage. The whole new approach has been verified and implemented on industrial equipment. A challenging task while implementing Industry 4.0 technologies is the issue of how to fully gather and analyse operational data from various items of equipment and users under various conditions, which would result in innovative services of equipment maintenance for clients. The solution to this problem is based on an innovative approach to preventive maintenance of complex equipment and could help many industrial companies to increase production and maintenance efficiency.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Quality and Management Systems · Transport and Logistics Innovations · Technology Assessment and Management

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Faculty of Science, University of Ostrava, 70103 Ostrav, Czech Republic

References (26)

Show source-provided references
1. Levitt, J. (2010). TPM Total Productive Maintenance, Industrial Press Inc.
2. Gross, J.M. (2008). Fundamentals of Preventive Maintenance, AMACOM Division of American Management Association International.
3. Ergonomics Program Management in Tucuruí Hydropower Plant using TPM Methodology10.3233/WOR-2012-0530-2822 ↗
4. Butlewski, M., Dahlke, G., Drzewiecka-Dahlke, M., Górny, A., and Pacholski, L. (2017, January 17–21). Implementation of TPM methodology in worker fatigue management—A macroergonomic approach. Proceedings of the International Conference on Applied Human Factors and Ergonomics, Los Angeles, CA, USA.10.1007/978-3-319-60828-0_4 ↗
5. A hybrid DBH-VNS for high-end equipment production scheduling with machine failures and preventive maintenance activities10.1016/j.cam.2020.113195 ↗
6. An active preventive maintenance approach of complex equipment based on a novel product-service system operation mode10.1016/j.jclepro.2020.123365 ↗
7. Preventive maintenance by production personnel using Total Productive Maintenance (TPM)
8. A Multistage Stochastic Programming Approach for Preventive Maintenance Scheduling of GENCOs with Natural Gas Contract10.1016/j.ejor.2020.03.036 ↗
9. Deep reinforcement learning based preventive maintenance policy for serial production lines10.1016/j.eswa.2020.113701 ↗
10. Poór, P., Basl, J., and Zenisek, D. (2019, January 28). Predictive Maintenance 4.0 as next evolution step in industrial maintenance development. Proceedings of the 2019 International Research Conference on Smart Computing and Systems Engineering (SCSE), Colombo, Sri Lanka.10.23919/SCSE.2019.8842659 ↗
11. Industry 4.0 and lean manufacturing10.1108/JMTM-12-2018-0446 ↗
12. Total productive maintenance (TPM) as a tool for improving productivity: A case study of application in the bottleneck of an auto-parts machining line10.1007/s00170-017-0052-4 ↗
13. Enhancement of Overall Equipment Effectiveness using Total Productive Maintenance in a Manufacturing Industry
14. Agustiady, T.K., and Cudney, E.A. (2018). Total productive maintenance. Total Qual. Manag. Bus. Excell.10.1080/14783363.2018.1438843 ↗
15. Evaluating 8 pillars of Total Productive Maintenance (TPM) implementation and their contribution to manufacturing performance10.1088/1757-899X/290/1/012024 ↗
16. Realyvásquez-Vargas, A., Arredondo-Soto, K.C., Carrillo-Gutiérrez, T., and Ravelo, G. (2018). Applying the Plan-Do-Check-Act (PDCA) cycle to reduce the defects in the manufacturing industry. A case study. Appl. Sci., 8.10.20944/preprints201810.0347.v1 ↗
17. Díaz-Reza, J.R., García-Alcaraz, J.L., Avelar-Sosa, L., Mendoza-Fong, J.R., Saenz Diez-Muro, J.C., and Blanco-Fernández, J. (2018). The role of managerial commitment and TPM implementation strategies in productivity benefits. Appl. Sci., 8.10.3390/app8071153 ↗
18. Implementation of total productive maintenance (tpm) to improve sheeter machine performance10.1051/matecconf/201713500028 ↗
19. Sima, V., Gheorghe, I.G., Subić, J., and Nancu, D. (2020). Influences of the industry 4.0 revolution on the human capital development and consumer behavior: A systematic review. Sustainability, 12.10.3390/su12104035 ↗
20. Industry 4.0: Tools and implementation
21. Leveraging optimized and cleaner production through industry 4.010.1016/j.spc.2021.01.001 ↗
22. Engin, B.E., Khajeh, E., and Paksoy, T. (2020). Lean Manufacturing and Industry 4.0: A Framework to Integrate the Two Paradigms. Logistics 4.0, CRC Press.10.1201/9780429327636-34 ↗
23. The role of additive manufacturing in the era of industry 4.010.1016/j.promfg.2017.07.148 ↗
24. Information management to improve the effectiveness of preventive maintenance activities with computerized maintenance management system at the intake system of circulating water pump10.1016/j.procir.2018.09.044 ↗
25. Suitable computerized maintenance management system selection using grey group TOPSIS and fuzzy group VIKOR: A case study10.5267/j.dsl.2018.3.002 ↗
26. A general framework of computerized maintenance management system for an automobile industry