Proposal for a maintenance management system based on the lean philosophy and industry 4.0

Abstract

Purpose: Develop a new model that combines the concepts of Maintenance, Lean Philosophy, and Industry 4.0 to improve maintenance management. Methodology/Approach: For the elaboration the following methodology was used: Bibliographic review of the existing models of joint application: Maintenance, Lean Philosophy, and Industry 4.0. Critical analysis of the existing models of joint application of the three concepts. Preparation of the model proposal and analysis of the results. Findings: The model developed is easy to apply, flexible and inexpensive, being a useful tool for both the maintenance and production areas, in any size and industrial area. Research Limitation/implication: One of the limitations is the distance between the devices that make up the system, as it can influence their performance. The implementation of Total Productive Maintenance can present some challenges within companies. Originality/Value of paper: The study presents a new model to improve maintenance management, being unique since the existing models are mostly focused on predictive maintenance. The system also allows the introduction of the monitoring of other important parameters such as vibrations, temperature among others.

The Maintenance Management

“…The determination of the maintenance policy is based primarily on the characters of the number of failures, the number of operating cycles of the equipment and the time of performing the part replacement according to the text [7]. Based on a search of publications and analysis, models are created, including together maintenance, lean production and the Industry 4.0 in the article [13]. Reducing maintenance costs while increasing production performance and assessing several scenarios in the maintenance is described in the publication [14].…”

“…The article [12] devotes to muscle and skeletal disorders in maintenance employees in connection with the risk assessment of these activities. Critical analysis of models that combine maintenance, lean manufacturing and the Industry 4.0, and design of its own for predictive maintenance is mentioned in the article [13]. Multi-target optimisation algorithm for wind turbine maintenance is used in the publication [14].…”

“…Many organisations have difficulty to implement the conception TPM and a spatial arrangement of equipment in a shopfloor as the article [13] describes. The eternal problem is to reduce maintenance costs and increase equipment availability for many articles as in [15,18].…”

“…The basis is the determination of suitable characters of the maintenance process and their use in sophisticated algorithms that help rapid planning, optimisation and management of maintenance and elimination of staff conflicts in publications [2,5]. Other factors influencing the maintenance are involved in the prediction, such as vibration [13], energy prices and spare parts wear [14]. It is necessary to establish common characters or metrics for the production process and the maintenance process [4,16].…”

Capacidade tecnológica e abordagem enxuta em micro, pequenas e médias empresas industriais brasileiras

“…Vale destacar também os estudos que propõem modelos voltados para a melhoria do desempenho operacional da manutenção industrial a partir de diferentes abordagens, ou seja, combinando aspectos da filosofia enxuta com elementos da recente proposta de congruência de tecnologias da denominada indústria 4.0 (Islas, Gutierrez & Rodríguez, 2019;Kinz, Bernerstätter & Biedermann, 2016;Magadán, Suárez, Granda & Garcia, 2020;Mendes, Navas & Charrua-Santos, 2022;Shahin, Chen, Bouzary & Krishnaiyer, 2020). Contudo, implementações enxutas bemsucedidas costumam contemplar simultaneamente aspectos sociais e técnicos (Tortorella, Fettermann & Vergara, 2018).…”