{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,4,29]],"date-time":"2026-04-29T18:28:59Z","timestamp":1777487339526,"version":"3.51.4"},"reference-count":40,"publisher":"MDPI AG","issue":"7","license":[{"start":{"date-parts":[[2023,6,28]],"date-time":"2023-06-28T00:00:00Z","timestamp":1687910400000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"DOI":"10.13039\/501100001871","name":"Funda\u00e7\u00e3o para a Ci\u00eancia e Tecnologia","doi-asserted-by":"publisher","award":["UIDB\/00667\/2020"],"award-info":[{"award-number":["UIDB\/00667\/2020"]}],"id":[{"id":"10.13039\/501100001871","id-type":"DOI","asserted-by":"publisher"}]},{"DOI":"10.13039\/501100001871","name":"Funda\u00e7\u00e3o para a Ci\u00eancia e Tecnologia","doi-asserted-by":"publisher","award":["UIDB\/00151\/2020"],"award-info":[{"award-number":["UIDB\/00151\/2020"]}],"id":[{"id":"10.13039\/501100001871","id-type":"DOI","asserted-by":"publisher"}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Processes"],"abstract":"<jats:p>As the global market becomes increasingly competitive and demanding, companies face the challenge of responding swiftly and efficiently to customer needs. To maintain a competitive advantage, organisations must optimise the usage of their assets. This study focuses on the critical role of maintenance management and presents a novel, cost-effective, and easily applicable model that integrates Industry 4.0 (I4.0) and Total Productive Maintenance (TPM) principles to enhance production processes. The proposed model incorporates a real-time monitoring system equipped with sensors, a gateway, and Internet of Things (IoT) services. These components enable data acquisition, transmission, storage, and visualisation through both mobile and fixed devices. The model\u2019s effectiveness was validated through its implementation on a conveyor belt in a feed mill. The availability of the conveyor belt was around 89.5% before TPM implementation. After the implementation of TPM, it was possible to observe that the availability of the treadmill increased to 92.7% in a workweek of 105 h. On the other hand, it was possible to observe a considerable improvement in terms of the average time of each intervention, with a reduction of around 53%. Moreover, the model also facilitated improvements in the maintenance plan for the conveyor belt. Operators were trained to effortlessly comply with the new autonomous maintenance plan, enhancing operational efficiency. The joint application of I4.0 and TPM demonstrated significant advancements in maintenance management. The flexibility of the developed model allows for easy adaptation to monitor other condition parameters, enabling real-time decision-making for both the maintenance and production departments. This integrated approach holds the potential to drive process optimisation, ultimately contributing to improved productivity, cost-effectiveness, and competitiveness.<\/jats:p>","DOI":"10.3390\/pr11071956","type":"journal-article","created":{"date-parts":[[2023,6,29]],"date-time":"2023-06-29T00:49:47Z","timestamp":1687999787000},"page":"1956","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":24,"title":["Integrating TPM and Industry 4.0 to Increase the Availability of Industrial Assets: A Case Study on a Conveyor Belt"],"prefix":"10.3390","volume":"11","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-4242-4763","authenticated-orcid":false,"given":"David","family":"Mendes","sequence":"first","affiliation":[{"name":"Department of Mechanical Engineering, ESTSet\u00fabal, Instituto Polit\u00e9cnico de Set\u00fabal, 2910-761 Set\u00fabal, Portugal"},{"name":"Department of Electromechanical Engineering, Faculty of Engineering, University of Beira Interior, 6201-001 Covilh\u00e3, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-1691-1709","authenticated-orcid":false,"given":"Pedro D.","family":"Gaspar","sequence":"additional","affiliation":[{"name":"Department of Electromechanical Engineering, Faculty of Engineering, University of Beira Interior, 6201-001 Covilh\u00e3, Portugal"},{"name":"C-MAST, Center for Mechanical and Aerospace Science and Technologies, University of Beira Interior, 6201-001 Covilh\u00e3, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-2038-0237","authenticated-orcid":false,"given":"Fernando","family":"Charrua-Santos","sequence":"additional","affiliation":[{"name":"Department of Electromechanical Engineering, Faculty of Engineering, University of Beira Interior, 6201-001 Covilh\u00e3, Portugal"},{"name":"C-MAST, Center for Mechanical and Aerospace Science and Technologies, University of Beira Interior, 6201-001 Covilh\u00e3, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-4637-0755","authenticated-orcid":false,"given":"Helena","family":"Navas","sequence":"additional","affiliation":[{"name":"UNIDEMI, Department of Mechanical and Industrial Engineering, NOVA School of Science and Technology, Universidade NOVA de Lisboa, 2829-516 Caparica, Portugal"}]}],"member":"1968","published-online":{"date-parts":[[2023,6,28]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","unstructured":"Fortuna, G., and Gaspar, P.D. (2022). Implementation of industrial traceability systems: A case study of a luxury metal pieces manufacturing company. Processes, 10.","DOI":"10.3390\/pr10112444"},{"key":"ref_2","first-page":"73","article-title":"Effects of the use of digital technologies on the performance of firms in a developing country: Are there differences between creative and manufacturing industries?","volume":"10","author":"Vergara","year":"2022","journal-title":"Int. J. Inf. Syst. Proj. Manag."},{"key":"ref_3","doi-asserted-by":"crossref","unstructured":"Proen\u00e7a, A.P., Gaspar, P.D., and Lima, T.M. (2022). Lean optimization techniques for improvement of production flows and logistics management: The case study of a fruits distribution center. Processes, 10.","DOI":"10.3390\/pr10071384"},{"key":"ref_4","doi-asserted-by":"crossref","unstructured":"Rojek, I., Jasiulewicz-Kaczmarek, M., Piechowski, M., and Miko\u0142ajewski, D. (2023). An artificial intelligence approach for improving maintenance to supervise machine failures and support their repair. Appl. Sci., 13.","DOI":"10.3390\/app13084971"},{"key":"ref_5","doi-asserted-by":"crossref","first-page":"545","DOI":"10.1108\/JQME-06-2020-0056","article-title":"Applying analytical hierarchy process (AHP) in selecting best maintenance strategies for newly established chemical fertilizers plants","volume":"28","author":"Jawwad","year":"2022","journal-title":"J. Qual. Maint. Eng."},{"key":"ref_6","doi-asserted-by":"crossref","first-page":"2","DOI":"10.21595\/mrcm.2021.22110","article-title":"Robust vibration-based faults diagnosis machine learning model for rotating machines to enhance plant reliability","volume":"1","author":"Sinha","year":"2021","journal-title":"Maint. Reliab. Cond. Monit."},{"key":"ref_7","first-page":"345","article-title":"Lean practices adoption in the Portuguese industry","volume":"14","author":"Martins","year":"2021","journal-title":"J. Ind. Eng. Manag."},{"key":"ref_8","doi-asserted-by":"crossref","first-page":"635","DOI":"10.1108\/IJQRM-11-2013-0185","article-title":"Maintenance management models: A study of the published literature to identify empirical evidence: A greater practical focus is needed","volume":"32","author":"Fraser","year":"2015","journal-title":"Int. J. Qual. Reliab. Manag."},{"key":"ref_9","first-page":"347","article-title":"Imperfect economic production quantity models under predictive maintenance and reworking","volume":"7","author":"Tsao","year":"2020","journal-title":"Int. J. Syst. Sci. Oper. Logist."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"397","DOI":"10.1080\/09537287.2020.1741046","article-title":"A hybrid of industrial maintenance decision making grids","volume":"32","author":"Labib","year":"2021","journal-title":"Prod. Plan. Control."},{"key":"ref_11","doi-asserted-by":"crossref","unstructured":"Rivera-G\u00f3mez, H., Monta\u00f1o-Arango, O., Corona-Armenta, J.R., Garnica-Gonz\u00e1lez, J., Ortega-Reyes, A.O., and Anaya-Fuentes, G.E. (2019). JIT production strategy and maintenance for quality deteriorating systems. Appl. Sci., 9.","DOI":"10.3390\/app9061180"},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"10934","DOI":"10.1007\/s10489-021-03004-y","article-title":"Deep learning models for predictive maintenance: A survey, comparison, challenges and prospects","volume":"52","author":"Serradilla","year":"2022","journal-title":"Appl. Intell."},{"key":"ref_13","doi-asserted-by":"crossref","unstructured":"Natanael, D., and Sutanto, H. (2022). Machine Learning application using cost-effective components for predictive maintenance in industry: A tube filling machine case study. J. Manuf. Mater. Process., 6.","DOI":"10.3390\/jmmp6050108"},{"key":"ref_14","doi-asserted-by":"crossref","unstructured":"Zhao, J., Gao, C., and Tang, T. (2022). A review of sustainable maintenance strategies for single component and multicomponent equipment. Sustainability, 14.","DOI":"10.3390\/su14052992"},{"key":"ref_15","doi-asserted-by":"crossref","unstructured":"Werbi\u0144ska-Wojciechowska, S., and Winiarska, K. (2023). Maintenance performance in the age of Industry 4.0: A bibliometric performance analysis and a systematic literature review. Sensors, 23.","DOI":"10.3390\/s23031409"},{"key":"ref_16","doi-asserted-by":"crossref","first-page":"1622","DOI":"10.1108\/IJOPM-01-2014-0028","article-title":"Maintenance strategy selection and its impact in maintenance function: A conceptual framework","volume":"35","author":"Velmurugan","year":"2015","journal-title":"Int. J. Oper. Prod. Manag."},{"key":"ref_17","doi-asserted-by":"crossref","first-page":"304","DOI":"10.3390\/merits2040021","article-title":"Total Productive Maintenance, affective commitment and employee retention in apparel production","volume":"2","author":"Wickramasinghe","year":"2022","journal-title":"Merits"},{"key":"ref_18","doi-asserted-by":"crossref","unstructured":"Tortorella, G.L., Saurin, T.A., Fogliatto, F.S., Mendoza, D.T., Moyano-Fuentes, J., Gaiardelli, P., Seyedghorban, Z., Vassolo, R., Vergara, A.F.F.M.C., and Sunder, M.V. (2022). Digitalization of maintenance: Exploratory study on the adoption of Industry 4.0 technologies and total productive maintenance practices. Prod. Plan. Control., 1\u201321.","DOI":"10.1080\/09537287.2022.2083996"},{"key":"ref_19","doi-asserted-by":"crossref","unstructured":"D\u00edaz-Reza, J.R., Garc\u00eda-Alcaraz, J.L., Avelar-Sosa, L., Mendoza-Fong, J.R., S\u00e1enz Diez-Muro, J.C., and Blanco-Fern\u00e1ndez, J. (2018). The role of managerial commitment and TPM implementation strategies in productivity benefits. Appl. Sci., 8.","DOI":"10.3390\/app8071153"},{"key":"ref_20","doi-asserted-by":"crossref","unstructured":"Al-Refaie, A., Lepkova, N., and Camlibel, M.E. (2022). The relationships between the pillars of TPM and TQM and manufacturing performance using structural equation modeling. Sustainability, 14.","DOI":"10.3390\/su14031497"},{"key":"ref_21","first-page":"152","article-title":"Implementing total productive maintenance in a manufacturing small or medium-sized enterprise","volume":"14","author":"Xiang","year":"2021","journal-title":"J. Ind. Eng. Manag."},{"key":"ref_22","doi-asserted-by":"crossref","first-page":"286","DOI":"10.24867\/IJIEM-2021-4-295","article-title":"Selecting the best tools and framework to evaluate equipment malfunctions and improve the OEE in the cork industry","volume":"12","author":"Marinho","year":"2021","journal-title":"Int. J. Ind. Eng. Manag."},{"key":"ref_23","doi-asserted-by":"crossref","first-page":"186","DOI":"10.1080\/16843703.2019.1567664","article-title":"Operational reliability evaluation-based maintenance planning for automotive production line","volume":"17","author":"Soltanali","year":"2020","journal-title":"Qual. Technol. Quant. Manag."},{"key":"ref_24","doi-asserted-by":"crossref","unstructured":"C\u00e1rcel-Carrasco, J., and G\u00f3mez-G\u00f3mez, C. (2021). Qualitative analysis of the perception of company managers in knowledge management in the maintenance activity in the era of Industry 4.0. Processes, 9.","DOI":"10.3390\/pr9010121"},{"key":"ref_25","doi-asserted-by":"crossref","unstructured":"Hardt, F., Kotyrba, M., Volna, E., and Jarusek, R. (2021). Innovative Approach to preventive maintenance of production equipment based on a modified TPM methodology for Industry 4.0. Appl. Sci., 11.","DOI":"10.3390\/app11156953"},{"key":"ref_26","doi-asserted-by":"crossref","first-page":"927","DOI":"10.1080\/0951192X.2022.2028011","article-title":"Design, modelling, optimisation and validation of condition-based maintenance in IoT enabled hybrid flow shop","volume":"35","author":"Narayanan","year":"2022","journal-title":"Int. J. Comput. Integr. Manuf."},{"key":"ref_27","doi-asserted-by":"crossref","unstructured":"Ahmed, U., Carpitella, S., Certa, A., and Izquierdo, J. (2023). A feasible framework for maintenance digitalization. Processes, 11.","DOI":"10.3390\/pr11020558"},{"key":"ref_28","doi-asserted-by":"crossref","first-page":"4773","DOI":"10.1080\/00207543.2021.1956675","article-title":"Machine learning in manufacturing and industry 4.0 applications","volume":"59","author":"Rai","year":"2021","journal-title":"Int. J. Prod. Res."},{"key":"ref_29","unstructured":"Mendes, D.S., Navas, H.V., and Charrua-Santos, F.M. (2021, January 28). Relationship between Maintenance, Lean Philosophy, and Industry 4.0: Systematic literature review. Proceedings of the 14th European Professors of Industrial Engineering and Management, Graz, Austria."},{"key":"ref_30","doi-asserted-by":"crossref","first-page":"393","DOI":"10.1016\/j.promfg.2020.02.057","article-title":"Low-cost real-time monitoring of electric motors for the Industry 4.0","volume":"42","author":"Granda","year":"2020","journal-title":"Procedia Manuf."},{"key":"ref_31","doi-asserted-by":"crossref","first-page":"1184","DOI":"10.1016\/j.promfg.2020.10.166","article-title":"Frameworks proposed to address the threat of cyber-physical attacks to lean 4.0 systems","volume":"51","author":"Shahin","year":"2020","journal-title":"Procedia Manuf."},{"key":"ref_32","doi-asserted-by":"crossref","first-page":"1900109","DOI":"10.1002\/masy.201900109","article-title":"Lean manufacturing 4.0 of polymeric injection molding products","volume":"389","author":"Opran","year":"2020","journal-title":"Macromol. Symp."},{"key":"ref_33","first-page":"295","article-title":"Implementation of total productive maintenance lean tool to reduce lead time-A case study","volume":"8","author":"Ramakrishnan","year":"2017","journal-title":"Int. J. Mech. Eng. Technol."},{"key":"ref_34","doi-asserted-by":"crossref","unstructured":"Meddaoui, A. (2018, January 26). A new manufacturing improvement model based on overall equipment effectiveness and Lean maintenance. Proceedings of the Smart Application and Data Analysis for Smart Cities, Casablanca, Morocco.","DOI":"10.2139\/ssrn.3185329"},{"key":"ref_35","doi-asserted-by":"crossref","first-page":"1582","DOI":"10.1016\/j.promfg.2020.01.127","article-title":"Continuous improvement in maintenance: A case study in the automotive industry involving Lean tools","volume":"38","author":"Pinto","year":"2019","journal-title":"Procedia Manuf."},{"key":"ref_36","first-page":"126","article-title":"Total productive maintenance: Need & framework","volume":"2","author":"Parikh","year":"2015","journal-title":"Int. J. Innov. Res. Adv. Eng."},{"key":"ref_37","doi-asserted-by":"crossref","first-page":"1073","DOI":"10.1166\/asl.2015.6084","article-title":"A review on 5S and total productive maintenance and impact of their implementation in industrial organizations","volume":"21","author":"Talib","year":"2015","journal-title":"Adv. Sci. Lett."},{"key":"ref_38","doi-asserted-by":"crossref","first-page":"1880","DOI":"10.4028\/www.scientific.net\/AMM.675-677.1880","article-title":"Specific electrical energy consumption and CO2 emissions assessment of agrifood industries in the central region of Portugal","volume":"675\u2013677","author":"Silva","year":"2014","journal-title":"Appl. Mech. Mater."},{"key":"ref_39","doi-asserted-by":"crossref","unstructured":"Varandas, L., Faria, J., Gaspar, P.D., and Aguiar, M.L. (2020). Low-Cost IoT Remote Sensor Mesh for Large-Scale Orchard Monitorization. J. Sens. Actuator Netw., 9.","DOI":"10.3390\/jsan9030044"},{"key":"ref_40","doi-asserted-by":"crossref","first-page":"2013","DOI":"10.1080\/00405000.2017.1308786","article-title":"An application of Pareto analysis and cause-and-effect diagram (CED) to examine stoppage losses: A textile case from Bangladesh","volume":"108","author":"Hossen","year":"2017","journal-title":"J. Text. Inst."}],"container-title":["Processes"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/2227-9717\/11\/7\/1956\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,10,10]],"date-time":"2025-10-10T20:02:36Z","timestamp":1760126556000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/2227-9717\/11\/7\/1956"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2023,6,28]]},"references-count":40,"journal-issue":{"issue":"7","published-online":{"date-parts":[[2023,7]]}},"alternative-id":["pr11071956"],"URL":"https:\/\/doi.org\/10.3390\/pr11071956","relation":{},"ISSN":["2227-9717"],"issn-type":[{"value":"2227-9717","type":"electronic"}],"subject":[],"published":{"date-parts":[[2023,6,28]]}}}