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RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
Year IV, v.1, n.1, Jan/July 2024. | submission: 23/03/2024 | accepted: 25/03/2025 | publication: 27/03/2024
TPM and Industry 4.0: Integration of smart technologies in maintenance
Tpm and industry 4.0: integration of smart technologies in maintenance
Jefferson José Penha D'Addario
SUMMARY
This study addresses the integration between Total Productive Maintenance (TPM) and
Industry 4.0, highlighting the impact of emerging technologies on the modernization of
industrial maintenance practices. TPM, consolidated as an effective methodology for
maximizing equipment efficiency, has been enhanced by the advancement of Industry
4.0, which introduces the Internet of Things (IoT), Artificial Intelligence (AI), Big Data,
and cyber-physical systems. The convergence of these approaches has enabled the
transition from corrective and preventive maintenance models to more predictive and
prescriptive strategies, allowing for the early identification of failures and the reduction
of unscheduled downtime. The study discusses how smart sensors, machine learning
algorithms, and cloud computing have revolutionized maintenance management,
optimizing productivity and reducing operating costs. In addition, the research
highlights the positive impact of these technologies on quality management,
occupational safety, and employee training, promoting an organizational culture
focused on continuous improvement and innovation. The analysis indicates that the
adoption of these practices contributes to a more efficient, sustainable and competitive
industrial environment, ensuring greater predictability and reliability of production
assets. It is concluded that the modernization of maintenance, made possible by
Industry 4.0, represents a strategic differentiator for companies seeking operational
excellence and optimization of their production processes.
Keywords:Total Productive Maintenance (TPM). Operational Efficiency. Maintenance
Management. Equipment Availability.
ABSTRACT
The present study addresses the integration between Total Productive Maintenance
(TPM) and Industry 4.0, highlighting the impact of emerging technologies on the
modernization of industrial maintenance practices. TPM, established as an effective
methodology for maximizing equipment efficiency, has been enhanced by the
advancements of Industry 4.0, which introduces the Internet of Things (IoT), Artificial
Intelligence (AI), Big Data, and cyber-physical systems. The convergence of these
approaches has enabled the transition from corrective and preventive maintenance
1 models to more predictive and prescriptive strategies, allowing for early failure
detection and a reduction in unplanned downtime. The study discusses how smart
sensors, machine learning algorithms, and cloud computing are revolutionizing
maintenance management, optimizing productivity, and reducing operational costs.
This is an Open Access article distributed under the terms of the CreativeCommons Attribution License, which permits unrestricted use,
distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
Furthermore, the research highlights the positive impact of these technologies on
quality management, workplace safety, and employee training, fostering an
organizational culture focused on continuous improvement and innovation. The
analysis indicates that adopting these practices contributes to a more efficient,
sustainable, and competitive industrial environment, ensuring greater predictability and
reliability of productive assets. It is concluded that the modernization of maintenance,
enabled by Industry 4.0, represents a strategic advantage for companies seeking
operational excellence and process optimization.
Keywords:Total Productive Maintenance (TPM); Operational Efficiency; Maintenance
Management; Equipment Availability.
1 INTRODUCTION
Maintenance plays an essential role in the industrial environment,
directly influencing productivity and operational efficiency. Unexpected machine
failures during the production process can have significant impacts on the
production schedule, resulting in delays, increased overtime costs, and the need for
rework to minimize losses. In addition, the lack of effective maintenance strategies
can compromise profitability and even the survival of the business, since inefficient
equipment reduces production capacity and increases waste of resources (Marques;
Brito, 2019).
In this context, companies that adopt lean production principles andjust-in-
timeconstantly seek to eliminate waste and optimize industrial processes.
Equipment reliability becomes a strategic factor for reducing stocks, ensuring the
delivery of products with higher quality standards and lower rates of scrap and
rework. Thus, investing in more efficient maintenance practices not only improves
operational performance, but also strengthens the competitiveness and
sustainability of industries (Silvaet al., 2018).
One of the most effective methodologies for ensuring equipment reliability
and optimizing production processes is Total Productive Maintenance (TPM). This
approach aims to maximize the efficiency of industrial assets through the active
participation of employees at different organizational levels, promoting a culture of
2 continuous improvement and failure prevention. Its principles include autonomous
maintenance, team training, and the adoption of systematic strategies to reduce
failures and production losses (Ribeiro, 2014). The application of TPM has proven to
be essential for minimizing waste, improving quality, and
This is an Open Access article distributed under the terms of the CreativeCommons Attribution License, which permits unrestricted use,
distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
of products and increase the reliability of processes, ensuring operational stability
and contributing directly to the competitiveness of companies (Ribeiro, 2014).
With the advances of Industry 4.0, new technologies have been incorporated
into industrial processes, promoting a more automated, interconnected and
intelligent production environment. The introduction of cyber-physical systems, the
Internet of Things (IoT), Artificial Intelligence (AI), Big Data and cloud computing has
revolutionized the way industries manage their assets and production processes.
These technologies allow the collection and analysis of large volumes of data in real
time, facilitating the implementation of predictive and prescriptive maintenance
strategies that anticipate failures and optimize the useful life of equipment (Borlido,
2017).
The integration of TPM with Industry 4.0 concepts represents a significant
advance in industrial maintenance management, enabling greater predictability of
failures, reduction of unscheduled downtime, and increased operational efficiency.
Smart sensors combined with machine learning systems allow equipment to be
continuously monitored, identifying wear patterns and suggesting interventions
before critical failures occur. In addition, predictive analysis based on historical and
real-time data contributes to more efficient maintenance planning, reducing
operating costs and increasing productivity (Viannini; Miranda Junior, 2020).
Given this scenario, this study aims to analyze the convergence between Total
Productive Maintenance and emerging technologies of Industry 4.0, investigating
how this integration can improve industrial maintenance practices and increase the
competitiveness of organizations. The research aims to demonstrate that the
application of technological solutions in maintenance management not only
enhances the benefits of TPM, but also represents a strategic differentiator for
companies seeking greater efficiency and sustainability in their production
processes.
2 DEVELOPMENT
3
2.1 Total Productive Maintenance (TPM): concept, pillars and benefits
This is an Open Access article distributed under the terms of the CreativeCommons Attribution License, which permits unrestricted use,
distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
Total Productive Maintenance (TPM) is a management methodology that
originated in Japan in the 1970s and aims to maximize the efficiency of industrial
equipment by involving all employees in the maintenance and continuous
improvement of production processes. The main objective of TPM is to eliminate
losses, reduce unscheduled downtime and ensure product quality, promoting an
organizational culture of shared responsibility (Ribeiro, 2014).
According to Nakajima (1989), the main objectives of TPM are to increase
equipment reliability, eliminate failures and optimize machine availability in the
industrial environment. To achieve these results, the methodology promotes
integrated management between operators and equipment, encouraging structural
improvements in the company. In this context, technical training of employees
becomes essential, since it strengthens awareness of the importance of the
performance of productive assets. However, training represents a long-term
investment, providing benefits such as the formation of multifunctional operators, a
greater sense of responsibility, reduced repair time and more efficient collaboration
between operational and maintenance teams.
TPM is a management methodology developed in Japan, whose main
objective is to maximize the efficiency of industrial equipment, reducing failures and
promoting the continuous improvement of production processes. According to
Nakajima (1989), TPM involves the active participation of all company employees,
from operators to senior management, creating a work environment where
maintenance is seen as a shared responsibility. This approach aims to eliminate
waste and improve the overall performance of the organization.
The TPM structure is based on eight fundamental pillars, which serve as
guidelines for the effective implementation of the methodology. The first pillar, Focused
Improvement, seeks to eliminate losses that negatively impact production efficiency,
using methodologies such as the PDCA cycle and the Ishikawa diagram to identify and
solve problems at the root (Ribeiro, 2014). The application of this pillar allows significant
gains in equipment reliability and in the reduction of recurring failures.
4 The second pillar, Autonomous Maintenance, encourages operators to take a
more active role in maintaining equipment by performing daily inspections, cleaning
and minor preventive maintenance. This practice helps to increase awareness of the
condition of machines and prevent failures before they cause problems.
This is an Open Access article distributed under the terms of the CreativeCommons Attribution License, which permits unrestricted use,
distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
impacts on production (Tsuchiya, 1992). In this way, operators become more
responsible for the equipment they use daily.
Planned Maintenance represents the third pillar of TPM and is focused on
establishing systematic strategies for preventive and predictive maintenance.
According to Wireman (2005), this approach is based on the analysis of historical
equipment data, enabling more efficient planning and reducing the need for
corrective maintenance. This practice contributes directly to machine reliability and
the reduction of unscheduled downtime.
The fourth pillar, Education and Training, is essential to ensure that
employees have the necessary knowledge to operate and maintain equipment
efficiently. For Nakajima (1989), the continuous development of employees improves
the technical capacity of the team, reducing operational errors and strengthening
the culture of continuous improvement within the company. In this way, training
becomes a long-term investment for the organization.
The fifth pillar, Anticipatory Management, aims to predict failures and
continually improve equipment to meet future demands. According to Shirose
(1996), this practice is based on the collection and analysis of maintenance data,
allowing industries to anticipate problems and adopt solutions before they impact
production. This approach reduces costs and improves asset availability.
The sixth pillar, Quality Maintenance, is directly related to ensuring that
equipment operates in a way that prevents product defects. According to Jostes and
Helms (1994), equipment failures can compromise the final quality of the product,
increasing rework and waste. The application of this pillar ensures that machine
conditions are always optimized for production with high quality standards.
Safety is also an essential aspect of TPM, represented by the seventh pillar,
Safety, Health and Environment (SSMA). According to Ahuja and Khamba (2008), the
integration of this pillar into the industrial routine reduces work accidents and improves
the ergonomic conditions of operators. Furthermore, sustainable practices in productive
maintenance minimize the environmental impact of industrial operations.
5 The eighth pillar, Office TPM, deals with the application of continuous improvement
concepts in administrative management. According to Bhadury (2000), this initiative seeks to
eliminate waste in administrative processes, ensuring greater efficiency in document
management, inventory control and communication between sectors.
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distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
In this way, TPM expands beyond the factory floor, impacting the entire organizational
structure.
The adoption of these eight pillars brings several benefits to organizations,
including increased equipment reliability, reduced operating costs and improved
product quality. According to Rodrigues and Hatakeyama (2006), TPM promotes
integration between the maintenance and production sectors, resulting in more
efficient processes and an organizational culture focused on excellence.
Furthermore, by encouraging employee involvement, the methodology improves
team motivation and engagement, strengthening industrial competitiveness.
2.2 Industry 4.0: concept, principle, main technologies and impact on
manufacturing
Industry 4.0, also known as the Fourth Industrial Revolution, is a revolutionary
model that encompasses various technological innovations, mainly in the fields of
automation, control and technology. Schwab (2016) indicates that Industry 4.0, or the
Fourth Industrial Revolution, goes beyond connected systems and machines. The
difference between this revolution and previous ones is the fusion and interaction of
technologies from various areas of knowledge, such as physical, digital and biological.
For Morais and Monteiro (2017), based on the concepts of innovation, the Industry
Industry 4.0 emerges as a set of disruptive innovations that have major impacts on
operational concepts, characterized by the increasing digitalization and
interconnection of products, value chains and business models, centered on the
intelligent production of products, methods and processes (Smart Production). The
smart factory is an important element of Industry 4.0, as it dominates complexity, is
less susceptible to human interference and increases production efficiency. In the
smart factory, communicating with people, machines and resources will be as
natural as in a social network context, and the paradigm shift required for Industry
4.0 is a long-term project and is only just beginning.
6
Industry 4.0 enables greater automation of tasks, which means that workers
must be prepared to perform new tasks. The same applies to engineering
education, which has great potential to train
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distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
professionals of the future and make them aware of new technological trends and
opportunities. Managers must also adapt their management strategy to new market
requirements (Erolet al., 2016).
According to Rübmannet al. (2015), these advances are possible due to
technological advances seen in the last decade, combined with advances in the
areas of information technology and engineering. According to the authors, there
are nine axes that support this development and that allow sensors, machines, tools
and information technologies to be connected throughout the entire production
chain: Big Data and data analysis, robotics, simulation, Internet of Things,
cybersecurity, cloud computing, horizontal and vertical integration systems,
augmented reality and additive processes.
Industry 4.0 has the potential to significantly impact management and the job
market in the future, enabling the creation of new business models with broad
influence on the industry and markets. These transformations affect the entire
product life cycle, redefining production processes and business strategies.
Furthermore, the adoption of these innovations promotes the optimization of
industrial processes, improving operational efficiency and strengthening the
competitiveness of companies in the global scenario (Pereira; Romero, 2017).
Industry 4.0 has had a profound impact on manufacturing,
transforming production processes and driving gains in efficiency, quality and
flexibility. According to Kagermann, Wahlster and Helbig (2013), automation and
digitalization enable greater integration between production systems, enabling real-
time decision-making and the adaptation of manufacturing processes to market
demands in a more agile manner. This evolution reduces production times and
minimizes waste, contributing to more sustainable industrial management.
In addition to optimizing production, Industry 4.0 has had a significant impact
on industrial maintenance. According to Lee, Bagheri and Kao (2015), the
implementation of cyber-physical systems enables the application of predictive
maintenance, in which smart sensors continuously monitor equipment conditions
and anticipate failures before they compromise production. This approach reduces
7 operating costs and improves the reliability of industrial assets, avoiding
unscheduled downtime and increasing equipment availability.
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distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
Another direct effect of Industry 4.0 on manufacturing is mass customization.
According to Frank, Dalenogare and Ayala (2019), the digitalization of production
processes allows companies to adapt production to the specific needs of customers,
ensuring customized products without compromising the efficiency of the
production line. This results in greater competitiveness and the ability to serve
increasingly segmented markets, expanding business opportunities.
The adoption of Industry 4.0 also impacts logistics within industrial plants. For
Ivanov, Dolgui and Sokolov (2019), the interconnectivity between machines and systems
allows for more efficient management of the supply chain, reducing unnecessary stocks
and improving the flow of materials. This improvement in internal logistics contributes
to leaner and more integrated production, strengthening the competitiveness of
companies in the global scenario.
Industry 4.0 has also brought about changes in the profile of the industrial
workforce. According to Pfeiffer, Siemsen and Abele (2021), the digitalization and
automation of production processes require professionals with new skills, focused
on data analysis, programming and operation of intelligent systems. This has led
industries to invest in training programs to prepare workers for the challenges of
digital manufacturing, ensuring adaptation to the new technological scenario.
2.3 The relationship between TPM and Industry 4.0: modernizing maintenance
TPM and Industry 4.0 represent innovative approaches that, when integrated,
promote a profound transformation in industrial maintenance. TPM, created in
Japan, aims to maximize equipment efficiency, involving all employees in the search
for continuous improvement of production processes. In parallel, Industry 4.0
brings with it a set of advanced technologies, such as the Internet of Things (IoT),
Artificial Intelligence (AI) and Big Data, which enable the creation of highly
intelligent and interconnected production environments. The combination of these
approaches not only improves maintenance management, but also increases the
8 competitiveness and operational efficiency of companies (Souza, 2022).
The convergence between TPM and Industry 4.0 changes the traditional
approach to industrial maintenance, making it increasingly predictive and less reactive.
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distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
The implementation of IoT sensors in equipment allows for the continuous
collection of operational data in real time. This information is analyzed by AI
systems, which identify behavior patterns and anticipate possible failures. This
advancement enables preventive interventions and drastically reduces the number
of unexpected shutdowns, in line with the TPM principles of eliminating losses and
maximizing productivity (Silvestri et al., 2020).
In addition to predictive maintenance, autonomous maintenance, one of the
fundamental pillars of TPM, is significantly enhanced by Industry 4.0. According to
Carvalho (2022), operators equipped with mobile devices, augmented reality
interfaces, and remote monitoring software can monitor machine performance in
real time, perform periodic inspections, and perform basic interventions with
greater precision and agility. This new paradigm reduces the dependence on
specialized teams for simple activities, while increasing operator autonomy,
improving equipment reliability, and reducing response times for fault correction.
Planned maintenance also benefits directly from the analysis of historical and
real-time data provided by Big Data. Based on detailed information about
equipment performance, it becomes possible to schedule interventions in an
optimized way, ensuring that maintenance is carried out at the right time. This
approach reduces operating costs, increases the useful life of assets and improves
the reliability of industrial systems. The ability to predict failures before they impact
production also promotes greater stability in processes, minimizing financial losses
resulting from unscheduled shutdowns (Silvestri et al., 2020).
In addition to operational gains, employee training has become more
effective with the use of digital technologies applied to corporate education. E-
learning platforms, virtual simulators, and augmented reality enable interactive and
personalized training, allowing employees to acquire practical knowledge in a
dynamic and efficient way. These tools facilitate the learning of new methodologies
and technologies, ensuring that workers are prepared to deal with the complexity of
Industry 4.0 systems. The strengthening of the culture of continuous improvement
9 driven by these resources consolidates a more innovative and productive work
environment (Lima; Silva, 2018).
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distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
Quality management also benefits from the integration between TPM and Industry
4.0. The incorporation of real-time monitoring systems ensures that any deviation in
production processes is detected immediately, enabling the implementation of
corrective actions without compromising production efficiency. This constant
monitoring helps reduce product defects, minimizes rework, and improves the
standardization of industrial quality. As a result, companies are able to increase
customer satisfaction and increase their competitiveness in the global market
(Aguiar et al., 2019).
In terms of safety, health and environment (SSMA), the adoption of Industry
4.0 technologies redefines the way risks are managed in the manufacturing
environment. Environmental sensors monitor temperature, noise levels, air quality
and vibrations in equipment, ensuring safer conditions for workers. In addition,
wearable devices and AI algorithms are capable of identifying behavior patterns that
indicate fatigue or ergonomic risk, triggering preventive alerts to avoid accidents
and promote a safer and more sustainable work environment (Silva et al., 2021).
Administrative maintenance management is also modernized with the
integration of TPM and digital technologies. Enterprise Resource Planning (ERP) and
Computerized Maintenance Management Systems (CMMS) provide a unified, real-
time view of all maintenance processes, facilitating strategic decision-making. This
digitalization of operations reduces waste, optimizes workflows, and improves
communication between company sectors, making management more efficient and
aligned with the demands of Industry 4.0 (Carvalho, 2022).
Another relevant innovation is in the initial management of products, which
now considers maintenance and operational efficiency aspects at the design stage
of industrial projects. The use of digital models, digital twins and computer
simulations makes it possible to anticipate possible failures and optimize
components even before they are manufactured. This alignment between product
engineering and maintenance engineering favors the creation of more reliable and
easy-to-maintain equipment, reducing costs throughout the life cycle of industrial
10 assets (Silvestri et al., 2020).
In this way, the integration between TPM and Industry 4.0 promotes a significant
advance in the modernization of industrial maintenance. In addition to increasing
operational efficiency, this convergence strengthens the organizational culture around
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distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
continuous improvement and drives innovation within companies. The use of
advanced technologies not only optimizes production processes, but also provides a
safer, more sustainable and competitive environment, ensuring that the industry is
prepared for the challenges of the digital age.
3 FINAL CONSIDERATIONS
The evolution of industrial maintenance practices has been a determining
factor for the efficiency and competitiveness of organizations. TPM emerged as a
methodology capable of reducing failures, optimizing processes and involving
employees in the search for continuous improvements. However, the increasing
complexity of production systems and the need for greater predictability of failures
required the adoption of new strategies to ensure operational reliability. In this
scenario, Industry 4.0 brought a set of technological innovations that expand the
possibilities of maintenance, making it more intelligent, efficient and predictive. The
combination of these approaches has driven a structural transformation in the way
companies manage their production assets.
The integration between TPM and Industry 4.0 allows traditional maintenance
practices to evolve from a corrective and preventive approach to predictive and
prescriptive maintenance, based on real-time data analysis and artificial intelligence.
The use of smart sensors, IoT and Big Data enables the collection and processing of
operational information with a high degree of precision, anticipating failures and
significantly reducing machine downtime. In this way, maintenance becomes more
strategic, reducing operational costs and improving production efficiency. In
addition, the modernization of processes positively impacts product quality,
environmental sustainability and worker safety, reinforcing the fundamental pillars
of TPM.
Another relevant aspect of this convergence is employee training. With the
digitalization of maintenance, professionals need to develop new skills to operate
11 and interpret the integrated systems of Industry 4.0. Tools such as augmented
reality, artificial intelligence and virtual simulators make learning more dynamic and
interactive, ensuring that operators can act more efficiently and autonomously.
Thus,
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distribution, and reproduction in any medium, provided the original work is properly cited.
RCMOS – Multidisciplinary Scientific Journal of Knowledge.
ISSN: 2675-9128. São Paulo-SP.
Maintenance modernization not only improves the management of industrial
assets, but also strengthens the organizational culture focused on innovation and
continuous development of teams.
Given this scenario, it can be concluded that the integration between TPM
and Industry 4.0 represents a significant advance for industrial maintenance,
ensuring greater predictability, reliability and efficiency of production processes.
This synergy not only optimizes the use of resources, but also promotes a safer,
more sustainable work environment that is aligned with the demands of the global
market. Companies that invest in this modernization not only reduce costs and
operational losses, but also strengthen their competitiveness and capacity for
innovation. Therefore, the adoption of these strategies should not be seen only as a
technological trend, but as an imperative for organizations seeking operational
excellence and differentiation in the industrial sector.
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