Smart Manufacturing: Lean-TPM 4.0 Model with IoT and AI to Improve Innovation and Efficiency in the Refractory Industry

Abstract

Low efficiency in refractory production is a critical problem that affects both the profitability and sustainability of manufacturing processes. This study proposes an innovative model that integrates Lean and TPM 4.0 tools supported by IoT and artificial intelligence technologies. The proposal seeks to increase operational efficiency, reduce equipment downtime and mitigate high rework rates, thus contributing to greater productivity and lower operating costs. The model was applied in a company in the refractory crucible manufacturing sector, demonstrating a direct and significant impact on the efficiency of the production process. After its implementation, relevant improvements were observed: the porous crucible rate was reduced by 57.69 % (from 18.20 % to 7.70 %); the MTBF of the press increased by 24.34 % (from 173.06 h to 216.91 h), while the MTBF of the mixer increased by 50.43 %. Likewise, the internal configuration time decreased by 27.58%, from 83.60 h to 60.54 h. Finally, it is proposed that the model has the potential to be applied in other industrial environments, as it constitutes a scalable, flexible solution aimed at strengthening competitiveness and sustainability through the intelligent digitalization of maintenance processes.