Enhanced Real-Time Maintenance Management Model—A Step toward Industry 4.0 through Lean: Conveyor Belt Operation Case Study

Conveyor belts (CBs) are widely used for the continuous transport of bulk materials. CBs must be extremely reliable due to cost associated with their failure in production systems. Thus, it is highly relevant terms maintenance and planning find solutions reduce existing stoppages from these assets. In this sense, essential monitor collect real-time data piece equipment. This work presents a case study, where model that combines Lean Philosophy, Total Productive Maintenance (TPM), enabling technologies Industry 4.0 applied CB. The proposed monitors CB provides on its operation, which, using calculation indicators, allows more accurate thorough view evaluation, contributing improving supporting decision making by those responsible maintenance. collected sensor help production, readjustment optimized planning, programming, execution, areas. During field test two-hour monitoring period (10 a.m. 12 p.m.), identified six stoppages, resulting approximately 88.6% operational time conveyor. showed can result than conventional approaches. research also contributes advancement electronics industrial automation sectors empowering companies transform methodologies. potential approach implications enhanced productivity overall performance therefore highlighted.