Integrating Industry 4.0 and Total Productive Maintenance for global sustainability

Abstract

PurposeThe integration of Total Productive Maintenance (TPM) and Industry 4.0 (I4.0) is an emerging model, and the global pressure of various stakeholders raises scepticism of any emerging model towards providing sustainability. Therefore, this research aims to identify and rank the potential significant drivers of an integrated model of I4.0 and TPM to guide manufacturing enterprises towards sustainability.Design/methodology/approachThis research follows a four-phase methodology including literature review and expert opinion to select the sustainability indicators and I4.0-integrated TPM key drivers, followed by employing the analytic hierarchy process approach for weight determination of sustainability indicators. The research then deploys the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) to prioritise the I4.0-integrated TPM key drivers based on their effect on various sustainability indicators. Finally, a sensitivity analysis is conducted to check the robustness of the TOPSIS.FindingsThe findings establish the top five most influential key drivers of an I4.0-integrated TPM system, which include top management support, formal I4.0 adoption program, mid-management involvement and support, solid TPM baseline knowledge and high engagement of the production team. These top drives can lead manufacturing firms towards sustainability.Research limitations/implicationsThe digitalisation of shop floor practices, such as TPM, could be adapted by shop floor managers and policymakers of manufacturing companies to deliver sustainability-oriented outcomes. In addition, this research may aid decision-makers in the manufacturing sector in identifying the most important drivers of I4.0 and TPM, which will assist them in more effectively implementing an integrated system of I4.0 and TPM to practice sustainability. The scope of TPM applicability is wide, and the current research is limited to manufacturing companies. Therefore, there is a huge scope for developing and testing the integrated system of I4.0 and TPM in other industrial settings, such as the textile, food and aerospace industries.Originality/valueThis research makes a first-of-its-kind effort to examine how an I4.0-integrated TPM model affects manufacturing companies' sustainability and how such effects might be maximised.

Critical challenges of integrating OPEX strategies with I4.0 technologies in manufacturing SMEs: a few pieces of evidence from developing economies

“…Various theories as well as research works in the past support the integration of OPEX strategies with digital technologies from a SMEs business perspective. Due to the interplay between IE 4.0 and OPEX, the sustainable production capabilities of SMEs have gradually improved (Leong et al, 2020;Samadhiya et al, 2022). Also, past researchers suggested that OPEX has the potential to arrange business and operations in a faster and more efficient manner and can enhance its profitability and competitive advantages (Kamble et al, 2019;Wahab et al, 2016).…”

“…Due to the interplay between IE 4.0 and OPEX, the sustainable production capabilities of SMEs have gradually improved (Leong et al. , 2020; Samadhiya et al. , 2022).…”

Identification of Criteria for Enabling the Adoption of Sustainable Maintenance Practice: An Umbrella Review

“…The recent review studies show that existing body of knowledge on the topic of sustainable maintenance within the domain of Industry 4.0 [6] and Industry 5.0 [22], i.e., Maintenance 5.0, is mostly concerned [23] with resilient, worker-in-the-loop and human-inthe-loop [11] maintenance research. It places the wellbeing of the worker at the centre of the production process, enabling the use advanced technologies that provide prosperity beyond jobs.…”

“…Rhetorically, SM goes beyond the traditional understanding of maintenance as a mere technical activity of condition monitoring, maintenance activities and planning [5]. In fact, it recognizes the interconnectedness between human activities, asset management and the environment, acknowledging the importance of sustainability challenges [6]. Such a holistic approach provides (1) a shift in traditional perception of maintenance as a "necessary evil" to "value-added activity" [7]; (2) transition from a short-term financial benefit to a long-term perspective; and (3) better understanding of the life cycle impacts of maintenance activities [8].…”

Reinforcement Learning-Based Optimization for Sustainable and Lean Production within the Context of Industry 4.0

“…Considering the lean part, the present paper adopts pull production and total productive maintenance, which are two well-known lean manufacturing techniques [28]. In this respect, pull production is enabled through ad hoc policies, such as Base Stock [29,30], while total productive maintenance is integrated through predictive maintenance policies, e.g., condition-based maintenance, that seek to minimize maintenance costs and improve the availability of processing machines [31]. The implemented ad hoc policies are frequently employed in the real-world industry and the academic literature [32,33].…”