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

Filip Hardt,Martin Kotyrba,Robert Jarusek,Eva Volna

doi:10.3390/app11156953

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.

Highlights

Introduction into the Problem AreaThe primary purpose of maintenance is to keep production and other equipment operational and prevent or minimise outages caused by conventional and unconventional failures
Maintenance in production plants is a very current topic since global optimisation of equipment maintenance results in minimisation of operational costs, both maintenance and production. It leads to an overall decrease in production equipment failures and an increase in production potential and effectivity
Basic division of preventive maintenance into blocks, see Figure 5: 1. Periodically repeated preventive maintenance—time-driven: AM; The proposed approach is completely unique and the innovative total productive maintenance (TPM) methodology can be implemented in various industrial companies to increase production and maintenance efficiency

Summary

Introduction into the Problem Area

The primary purpose of maintenance is to keep production and other equipment operational and prevent or minimise outages caused by conventional and unconventional failures. Repeated preventive maintenance—time-driven: AM (autonomous maintenance); The proposed approach is completely unique and the innovative TPM methodology can be implemented in various industrial companies to increase production and maintenance efficiency. For this reason, the results cannot yet be compared with other approaches. It has been adapted to rising trends and primary to the implementation of information systems within Industry 4.0 and digitalisation In this case, we present the proposed innovative way of preventive maintenance division into three logical units, which interconnect their usage, performed activities.

Standardisation of Processes

AM—Autonomous Maintenance

Findings

July 2020 PM