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Integration of Initial TPM Control into the Lifecycle of Industrial Assets: A Case Study in a Bulk Solid Cargo Port Terminal

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DOI:

https://doi.org/10.37497/opsbrazil.33

Keywords:

TPM, Reliability engineering, Initial control, Industrial maintenance, Asset lifecycle

Resumo

The management of complex industrial assets requires structured reliability approaches from the earliest design phases. In this context, this study analyzes the application of the Initial Control pillar of Total Productive Maintenance (TPM) throughout the lifecycle of industrial assets, based on a case study conducted in a bulk solid cargo port terminal.

The adopted methodology integrates reliability engineering, maintenance, and operational practices from the Front-End Loading (FEL) phases, using tools such as FMEA, criticality analysis, Reliability-Centered Maintenance (RCM) concepts, and hierarchical asset structuring. The study was carried out in a terminal with an annual handling capacity of 6 million tons and an investment of approximately BRL 800 million.

Results indicate a 19% reduction in maintenance plans, a 17% reduction in execution hours, and an 18% reduction in labor costs, in addition to increased reliability and operational availability. It is concluded that the application of Initial TPM Control significantly contributes to early failure mitigation, optimization of operational costs, and improved asset lifecycle performance.

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Biografia do Autor

Pedro Luis Corbett Morais, N&A Consultores, Salvador, Bahia, Brasil

Pedro Luis Corbett Morais is a consultant in reliability engineering and industrial asset management, with experience in the implementation and optimization of maintenance systems in complex industrial environments. He works on integrating Total Productive Maintenance (TPM), Reliability-Centered Maintenance (RCM), and reliability engineering principles throughout the lifecycle of industrial assets. His professional focus includes the development of maintenance strategies during engineering, commissioning, and early operational phases, aiming at cost reduction, improved reliability, and increased asset availability.

 

Referências

BLANCHARD, B. S. System Engineering Management. 3rd ed. New York: Wiley, 2004.

MOBLEY, R. K. An Introduction to Predictive Maintenance. 2nd ed. Burlington: Elsevier, 2002.

MOUBRAY, J. Reliability-Centered Maintenance. 2nd ed. New York: Industrial Press, 1997.

NAKAJIMA, S. Introduction to TPM: Total Productive Maintenance. Portland: Productivity Press, 1988.

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Postado

03-07-2026

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Copyright (c) 2026 Open Science Brazil

Creative Commons License
Este trabalho está licenciado sob uma licença Creative Commons Attribution 4.0 International License.