IMPLEMENTATION OF TOTAL PRODUCTIVE MAINTENANCE (TPM) TO ENHANCE RELIABILITY AND OPERATIONAL EFFICIENCY IN REFRACTORY MATERIAL HANDLING SYSTEMS: AN APPLIED STUDY BASED ON OEE, MTBF AND OPERATIONAL SUSTAINABILITY METRICS

Abstract

This study analyzes industrial maintenance as a strategic factor for ensuring the reliability, availability, and efficiency of production processes, with a focus on the refractory industry, which is characterized by high operational criticality and stringent safety requirements. The objective of the research is to evaluate the maintenance performance applied to a bucket elevator used for transporting refractory raw materials, identifying recurring failures and their impacts on productivity and operational efficiency. The adopted methodology consists of an exploratory and descriptive case study based on the analysis of maintenance records, performance indicators, and field observations. Parameters such as failure frequency, mean time between failures (MTBF), mean time to repair (MTTR), and overall equipment effectiveness (OEE) were evaluated in light of the principles of Total Productive Maintenance (TPM). The results indicate that the absence of a structured maintenance management system significantly contributes to the occurrence of unplanned downtime, negatively affecting equipment availability and overall production system performance. The systematic application of TPM-based practices demonstrated potential for failure reduction, improvement of performance indicators, and enhancement of the operational reliability of the analyzed equipment. It is concluded that the implementation of indicator-driven maintenance management aligned with TPM principles is essential for optimizing operational performance in refractory industries, contributing to reduced operating costs, increased production efficiency, and greater sustainability of industrial processes.