applied

sciences
Article
Digital Standardization of Lean Manufacturing Tools
According to Industry 4.0 Concept
Daniel Medyński 1 , Piotr Bonarski 1,2 , Piotr Motyka 1 , Adam Wysoczański 1,2,3 , Renata Gnitecka 1,4 ,
Krzysztof Kolbusz 1 , Magdalena Dabrowska
˛ 1 , Anna Burduk 5 , Zdzisław Pawelec 1 and José Machado 6, *

1 Department of Production Engineering and Logistics, Faculty of Technical and Economic Sciences, Witelon
Collegium State University, Sejmowa 5A, 59-220 Legnica, Poland;
[Link]@[Link] (D.M.); [Link]@[Link] (P.B.);
[Link]@[Link] (P.M.); [Link]@[Link] (A.W.);
[Link]@[Link] (R.G.); [Link]@[Link] (K.K.);
[Link]@[Link] (M.D.); [Link]@[Link] (Z.P.)
2 Technonicol-Insulation (Currently Boerner Insulation), Wyzwolenia 55, Wykroty,
59-730 Nowogrodziec, Poland
3 Industrial Support, Sejmowa 5A, 59-220 Legnica, Poland
4 Institute of Technology and Innovation, Witelon Collegium State University, Sejmowa 5A,
59-220 Legnica, Poland
5 Department of Laser Technologies, Automatization and Product Organization, Faculty of Mechanical
Engineering, Wroclaw University of Science and Technology, Wybrzeże Wyspiańskiego 27,
50-370 Wroclaw, Poland; [Link]@[Link]
6 MEtRICs Research Centre, School of Engineering, University of Minho, Campus of Azurém,
4800-058 Guimarães, Portugal
* Correspondence: jmachado@[Link]

Abstract: Standardization is a key element in the effective use of lean manufacturing methodologies
and tools for achieving process sustainability. Their combination is conducive to eliminating waste
and improving the efficiency of production processes and guarantees the company that employees
use the most efficient tools and do not waste time on unnecessary activities. These activities can
Citation: Medyński, D.; Bonarski, P.; be further improved by using digital solutions, in accordance with the concept of Industry 4.0.
Motyka, P.; Wysoczański, A.; Therefore, the authors have developed the e-Lean system, whose task is to digitize selected lean
Gnitecka, R.; Kolbusz, K.; Dabrowska,
˛ manufacturing tools. The subject of this work is analysis of the functionality and effectiveness of the
M.; Burduk, A.; Pawelec, Z.; essential part of the e-Lean system in the form of specialized TPM (Total Productive Maintenance)
Machado, J. Digital Standardization software as an application. During implementation in a construction production company, the TPM
of Lean Manufacturing Tools
application was tested by lean manufacturing and maintenance specialists. The research consisted
According to Industry 4.0 Concept.
of assessing the functionality and efficiency of processes in relation to conventional TPM solutions.
Appl. Sci. 2023, 13, 6259. https://
Additional functionalities of the e-Lean system have been confirmed, such as systemic approval of
[Link]/10.3390/app13106259
machinery inspection, which requires passing all necessary steps at individual inspection points,
Academic Editor: Mirco Peron direct access for supervisors to the results of inspection activities and their status, direct and easy
Received: 25 April 2023
access to photographic documentation of machines added during inspection both in optimization
Revised: 17 May 2023 of working time and its course (e.g., the optimal number of steps taken by the employee during
Accepted: 17 May 2023 the inspection), as well as an efficient system of motivating employees (collecting points). The
Published: 20 May 2023 improvement in the effectiveness of processes was determined by measuring the control times for
three control points (polymerization furnace, packing area, and defibering machines). The average
control time was reduced from 16,200 to 13,923 s. Thus, thanks to the use of the application, it was
found that the efficiency of using the TPM tool was increased by approx. 15% compared to previously
Copyright: © 2023 by the authors.
used non-digital solutions.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
Keywords: lean manufacturing tools; lean manufacturing methodologies; digital standardization;
distributed under the terms and
industry 4.0
conditions of the Creative Commons
Attribution (CC BY) license (https://
[Link]/licenses/by/
4.0/).

Appl. Sci. 2023, 13, 6259. [Link] [Link]

Appl. Sci. 2023, 13, 6259 2 of 16

1. Introduction
Lean manufacturing as a philosophy and methodology is used to manage and optimize
production processes. It puts emphasis on eliminating waste, improving production
efficiency and effectiveness, and increasing product quality and customer satisfaction. The
concept originated in Japan in the 1950s and is also known as the Toyota Production System
(TPS) because it was developed by Toyota. The main principles of lean manufacturing are
as follows [1–5]:
− Identify value from the customer’s perspective: determine what customers value and
what they are willing to pay for.
− Map the value stream: map the steps involved in producing a product or service and
identify areas where waste can be eliminated.
− Create flow: create a continuous flow of work through the system, reducing lead times
and work in progress.
− Establish pull: only produce what is needed when it is needed based on
customer demand.
− Seek perfection: continuously improve the system by eliminating waste and
improving efficiency.
Below are the most commonly used lean manufacturing tools that help achieve the
assumed goals [6–10]:
− 5S (used to create an optimal workplace, and its name is an acronym of five Japanese words:
1. Seiri (selection)—we separate all materials (instructions, tools) from each other
at the workplace and remove unnecessary things.
2. Seiton (organization)—we designate and mark tools and their parts.
3. Seiso (cleaning)—removing dirt, laying, cleaning, and renewing the workplace.
4. Seiketsu (standardization)—constantly keeping the workplace in order so it
remains clean and tidy (here we smoothly move on to the next tool).
5. Shitsuke (self-discipline)—habits and habits necessary to comply with the imple-
mented improvement solutions.
− Kaizen: means continuous improvement and consists of the continuous introduction
of changes and improvements with the help of small steps.
− Kanban: allows you to control production by events occurring directly in production.
− TPM, i.e., Total Productive Maintenance: this Comprehensive Productivity Mainte-
nance enables the activation of all employees and machines to maximize the total
efficiency of production resources.
− SMED, i.e., Single Minute Exchange of Die: literally translated as a one-minute ex-
change of a mold or tool that sets the goal of reducing changeover time to 10 min
or less.
− VSA, or Value Stream Analysis: value stream mapping, as the main lean tool, enables
visualization of information flow and the manufacturing process for selected products.
− Six Sigma: used to reduce costs and improve quality through the use of statistical tools.
− Poka-yoke: used to prevent errors from appearing through technical solutions, etc.
One of the key principles of lean manufacturing, allowing for the efficient implemen-
tation of lean tools, is the standardization of production processes, which consists of setting
standards of conduct that allow for the expected results to be achieved in a repeatable and
effective manner. The standardization of production processes comprises the creation of
unambiguous, defined procedures that are used at every stage of production. Within lean
manufacturing, the standardization process is often used, involving the use of tools such as
Standard Work and Standard Operating Procedures (SOPs). Standard Work is the descrip-
tion of an ideal production process including the time needed to complete individual tasks
by employees, while SOPs are detailed instructions for the production process [8–11]. The
standardization of production processes is therefore aimed at increasing the efficiency of
processes, reducing errors and deviations, and unifying the final results.
Appl. Sci. 2023, 13, 6259 3 of 16

In the context of lean manufacturing, standardization is extremely important for the

smooth functioning of the tools used in the lean manufacturing methodology and plays an
important role in eliminating waste and improving efficiency. By standardizing processes,
companies can ensure that workers are following the most efficient methods and are not
wasting time on unnecessary activities. Standardization also makes it easier to identify and
eliminate sources of waste and to track performance metrics over time.
The common goal of lean manufacturing and the standardization of manufacturing
processes is to improve production efficiency, with standardization focusing on ensuring
repeatability of results and lean manufacturing focusing on continuous process improve-
ment to ensure process efficiency and improve product quality. Thus, lean manufacturing
and standardization of production processes are two interrelated approaches to improv-
ing production efficiency. These activities can be improved by using digital solutions, in
accordance with the concept of Industry 4.0 [11–21].
Therefore, this work analyzes the functionality of the e-Lean system in terms of TPM,
which is the result of cooperation between Witelon Collegium State University, Industrial
Support, and Technonicol Insulation, where the system was implemented.

2. Methodology
One of the key lean manufacturing tools closely related to the standardization of
production processes is TPM. This tool allows you to achieve maximum efficiency with
production equipment by involving many employees in the maintenance process [22,23].
In addition, it enables efficient and ongoing diagnostics of machines and production
equipment, which requires monitoring of a number of parameters; it is very important from
the point of view of the operation of machine and equipment elements and the continuity
of production processes. The primary goal of TPM is to reduce equipment downtime,
minimize defects, and improve overall equipment effectiveness (OEE) by involving all
employees in the maintenance process [24–26]. This involves empowering operators to take
responsibility for the maintenance and improvement of their equipment and providing
them with the skills and knowledge necessary to do so. TPM also involves a focus on
continuous improvement, with the aim of eliminating losses and improving productivity
over time. The key elements of TPM include the following [27–32]:
− Autonomous maintenance: operators are trained to perform routine maintenance
tasks, such as cleaning, inspection, and lubrication, with the aim of preventing equip-
ment breakdowns and reducing the need for external maintenance support.
− Planned maintenance: maintenance activities are planned and scheduled in advance,
with the aim of minimizing downtime and optimizing maintenance resources.
− Quality maintenance: the focus is on eliminating defects and preventing their recur-
rence, with the aim of improving product quality and reducing waste.
− Training and development: employees are trained and developed to perform their
jobs effectively and to continuously improve their skills and knowledge.
− Equipment improvement: the aim is to continually improve equipment reliabil-
ity, maintainability, and operability, with the goal of increasing productivity and
reducing costs.
Overall, TPM is a comprehensive approach to maintenance and productivity improve-
ment that involves everyone in the organization, from top management to the shop floor.
By fostering a culture of continuous improvement and empowering employees to take
ownership of their equipment, TPM can lead to significant improvements in equipment
reliability, productivity, and quality [28,33].
In order to improve the TPM tool, specialized software was developed to improve
the maintenance of machine parks in continuous production readiness. It was assumed
that the e-Lean system would be installed on the company’s server and would cooperate
with the license server. System users with different levels of access to data, depending
on the assigned role, will be able to communicate with the enterprise server via a mobile
 In order to improve the TPM tool, specialized software was developed to improve
the maintenance of machine parks in continuous production readiness. It was assumed
that the e-Lean system would be installed on the company’s server and would cooperate
[Link] the
Sci. 2023, license server. System users with different levels of access to data, depending
13, 6259 4 ofon
16

the assigned role, will be able to communicate with the enterprise server via a mobile
application. The method of binding the key elements of the system installed on the license
application. The method of binding the key elements of the system installed on the license
server is shown in Figure server [Link] in Figure 1.

Figure 1. The main elements

Figure [Link] the
The e-Lean
main system
elements on the
of the e-Lean license
system server.
on the license server.

In turn, the main elements of the system and the method for data connections in the
In turn, the main elements of the system and the method for data connections in the
system installed on the server in the enterprise are shown in Figure 2.
system installed on the server in the
The method enterprise the
of implementing aresystem
shown in Figure
consists of three 2.
steps: installation, configu-
ration, and definition of machines and devices. On the other hand, the use of the system in
the enterprise includes three stages: TPM control, acceptance of the control results or their
rejection, and reporting, which is presented in the diagram in Figure 3.
The main functionalities of the system from the user’s point of view include managing
users and roles; defining machines, control points, and control methods; generating TPM
control actions; performing TPM checks; simple and detailed reporting; automatic sending
of control reports to selected groups; the creation of user statistics; assessment of the
machine’s condition; creation of general instructions and controls; and external training
and awards. Depending on the license package, the company can adapt the functionality
of the system to its needs.
In addition, the system enables data analysis and the forecasting of possible failures
based on the analysis of trends in the technical parameters of machines. The use of trend
models makes it possible to detect changes in the characteristics of the machine’s operation,
which may indicate an impending failure. Thus, it aims to anticipate future failures so that
preventive actions can be planned and unplanned machine downtime minimized.
Appl. Sci. 2023,
Appl. Sci. 13, x FOR
2023, PEER REVIEW
13, 6259 5 of 18
5 of 16

Figure 2. The main elements of the e-Lean system and data binding.
Figure 2. The main elements of the e-Lean system and data binding.

The method of implementing the system consists of three steps: installation, config-
uration, and definition of machines and devices. On the other hand, the use of the system
in the enterprise includes three stages: TPM control, acceptance of the control results or
their rejection, and reporting, which is presented in the diagram in Figure 3.
Appl.
[Link]. 2023,
Sci. 2023,13,
13,x 6259
FOR PEER REVIEW 6 of 1816
6 of

Figure
[Link]
Principleofofoperation
operationofofthe
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3. Results
The main andfunctionalities
Discussion of the system from the user’s point of view include manag-
ing users and roles;practice,
In industrial definingTPM machines, control
solutions points,
are most and
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forms,checks;
to whichsimple and
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The task ofautomatic
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facilitate groups;
access fromthethecreation ofthe
office to user statistics;
online assessment
inspection of
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all inspection instructions
books, but also to and controls;
enter and external
additional data, e.g.,train-
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ing andofawards.
photographic documentation.
Depending on the license Thanks to this,
package, theitcompany
is possiblecan
to adapt
monitor thethe status of
function-
technical
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system to itsofneeds.
machines and production equipment throughout the enterprise
fromInone place to
addition, thea system
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extent than databefore.
analysis and the forecasting of possible failures
based The TPM
on the application
analysis as an
of trends element
in the of the
technical advancedofe-Lean
parameters system,
machines. The which can be
use of trend
implemented in manufacturing enterprises without restrictions, applies
models makes it possible to detect changes in the characteristics of the machine’s opera- to the machine
parkwhich
tion, and users
may with different
indicate levels of access
an impending to Thus,
failure. data. Implementation of thefuture
it aims to anticipate e-Lean system
failures
soconsists of adding
that preventive relevant
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be planned from the point
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machine park in production readiness regarding, for example, machines and devices for
[Link]
Resultsany control
and points can be defined and users who can be given appropriate roles in
Discussion
the In
system in accordance
industrial practice, TPM with solutions
their competences and level
are most often of access to
implemented data adequate
through the use of for
their function in the company and others. The application installed on the server can be
paper documentation or digital forms, to which access is limited. The task of the tested
accessed from stationary and mobile devices (PCs, smartphones, tablets) located in offices,
application is not only to facilitate access from the office to the online inspection database,
as well as from the mobile devices of production employees. Figure 4 shows a screenshot
without the need to check all inspection books, but also to enter additional data, e.g., in
of the computer screen showing the license information for the system.
the form of photographic documentation. Thanks to this, it is possible to monitor the sta-
There is a system toolbar (Figure 4, item 1) that includes the functionality of the system.
tus of technical inspections of machines and production equipment throughout the enter-
Below, you can see data regarding the server’s ID and license activity status (Figure 4,
prise from one place to a greater extent than before.
item 2), as well as server settings (Figure 4, item 3) such as server address (Figure 4, item 4),
The TPM application as an element of the advanced e-Lean system, which can be
account login from which notifications are sent (Figure 4, item 5), server port (Figure 4,
implemented in manufacturing enterprises without restrictions, applies to the machine
item 6), the encryption used for communication with the server (Figure 4, item 7), and the
park and users with different levels of access to data. Implementation of the e-Lean system
e-mail address to be used when sending notifications (Figure 4, item 8).
consists of adding
Figure relevant
5 through data
Figure to thethe
6 show system from theofpoint
functionality of view
the TPM of maintaining
application regarding theits
machine park in production
users and their characteristics. readiness regarding, for example, machines and devices for
which any control points can be defined and users who can be given appropriate roles in
the system in accordance with their competences and level of access to data adequate for
their function in the company and others. The application installed on the server can be
Appl. Sci. 2023, 13, x FOR PEER REVIEW 7 of 18

accessed from stationary and mobile devices (PCs, smartphones, tablets) located in offices,
Appl. Sci. 2023, 13, 6259 7 of 16
as well as from the mobile devices of production employees. Figure 4 shows a screenshot
of the computer screen showing the license information for the system.

Appl. Sci. 2023, 13, x FOR PEER REVIEW 8 of 18

Figure 4. A screenshot of the TPM application showing the system’s license data.
Figure 4. A screenshot of the TPM application showing the system’s license data.

There is a system toolbar (Figure 4, item 1) that includes the functionality of the sys-
tem. Below, you can see data regarding the server’s ID and license activity status (Figure
4, item 2), as well as server settings (Figure 4, item 3) such as server address (Figure 4, item
4), account login from which notifications are sent (Figure 4, item 5), server port (Figure
4, item 6), the encryption used for communication with the server (Figure 4, item 7), and
the e-mail address to be used when sending notifications (Figure 4, item 8).
Figure 5 through Figure 6 show the functionality of the TPM application regarding
its users and their characteristics.

[Link]
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and the the
role assigned in the system, as well as the position in the
assigned in the system, as well as the position in the company. company.
The screenshot in Figure 6 shows the list of registered users, which, in addition to the
username (Figure 6, item 1), includes e-mail addresses (Figure 6, item 2), position (Figure
6, item 3), and assigned role in the system (Figure 6, item 4). In addition, there are function
fields on the right side labelled as Operations (Figure 6, item 5), which, after clicking, allow
you to view details about individual users, e.g., in terms of reports.
Appl. Sci. 2023, 13, 6259 8 of 16
Appl. Sci. 2023, 13, x FOR PEER REVIEW 9 of 18

Figure 6. Screenshot of the TPM application showing a list of users with their characteristics.
Figure 6. Screenshot of the TPM application showing a list of users with their characteristics.
The TPM application primarily contains functionality related to the maintenance of
The screenshot in Figure 6 shows the list of registered users, which, in addition to the
machinery and production equipment, which helps to improve production efficiency. The
username (Figure 6, item 1), includes e-mail addresses (Figure 6, item 2), position (Figure 6,
characteristics of the machinery and equipment must be entered into the system, and the
item 3), and
control assigned
points rolebeindefined
must then the system (Figure
(Figure 7) and6,pre-defined
item 4). Inchecks
addition, there are function
systematically car-
fields on the right side labelled as Operations
ried out according to the plan (Figure 8). (Figure 6, item 5), which, after clicking, allow
you to view details about individual users, e.g., in terms of reports.
The TPM application primarily contains functionality related to the maintenance of
machinery and production equipment, which helps to improve production efficiency. The
characteristics of the machinery and equipment must be entered into the system, and
the control points must then be defined (Figure 7) and pre-defined checks systematically
carried out according to the plan (Figure 8).
Figure 7 presents screenshots of application tabs showing defined checkpoints with
their characteristics, e.g., ID, name of the checkpoint, number of places to be verified,
weight, execution time, and the role of the employee in the system (Figure 7, item 1), as well
as a description concerning the performance of control activities (Figure 7, item 2). It is also
possible to place photographic documentation here (Figure 7, item 3), assign pictograms as
information indicators (Figure 7, item 4), and place instructions on how to proceed, e.g., in
a PDF, MP3 or AVI file (Figure 7, item 5).
The system allows you to schedule TPM checks (pressure gauge, oil level, etc.) at the
right time. Figure 8 shows the functionality of the system in terms of scheduling inspections
for a control point, which in this case is titled Tool holder control. Here, you can see the
control schedule based on a specific day of the week (Figure 8, item 1), as well as based on
a specific date (Figure 8, item 2).
Figure 9 shows a screenshot of the TPM application showing a list of sample check-
points. These are the checkpoints defined in the TPM check (Figure 9, item 1). Below,
they are listed respectively as tool holder control and machine power control (Figure 9,
item 2). Subsequently, the number of points to be assigned for the performance of the
control activity, their weight, and the time allocated to a given control point are visible
(Figure 9, item 3–5). There are also specialists assigned to a given checkpoint in terms
of their role (Figure 9, item 6) and there is also a place for a description of the operation
(Figure 9, item 7). Next, icons are displayed as information indicators for the checkpoint
(Figure 9, item 8), instructions for download (Figure 9, item 9), and option buttons for
details, icons, QR codes, corrections, and checkpoint removal (Figure 9, item 10).
 Figure 6. Screenshot of the TPM application showing a list of users with their characteristics.

The TPM application primarily contains functionality related to the maintenance of

machinery and production equipment, which helps to improve production efficiency. The
Appl. Sci. 2023, 13, 6259 9 of
characteristics of the machinery and equipment must be entered into the system, and16the
control points must then be defined (Figure 7) and pre-defined checks systematically car-
ried out according to the plan (Figure 8).

Appl. Sci. 2023, 13, x FOR PEER REVIEW 10 of 18

Appl. Sci. 2023, 13, x FOR PEER REVIEW 10 of 18

Figure 7. Screenshot of the TPM application defining checkpoints.

Figure 7 presents screenshots of application tabs showing defined checkpoints with

their characteristics, e.g., ID, name of the checkpoint, number of places to be verified,
weight, execution time, and the role of the employee in the system (Figure 7, item 1), as
well as a description concerning the performance of control activities (Figure 7, item 2). It
is also possible to place photographic documentation here (Figure 7, item 3), assign picto-
grams as information indicators (Figure 7, item 4), and place instructions on how to pro-
ceed, e.g., in a PDF, MP3 or AVI file (Figure 7, item 5).
The system allows you to schedule TPM checks (pressure gauge, oil level, etc.) at the
right time. Figure 8 shows the functionality of the system in terms of scheduling inspec-
tions for a control point, which in this case is titled Tool holder control. Here, you can see
the control
Figure [Link] based
Screenshot onTPM
of the a specific day of
application the week
defining (Figure 8, item 1), as well as based
checkpoints.
Figure 7. Screenshot of the TPM application defining checkpoints.
on a specific date (Figure 8, item 2).
Figure 7 presents screenshots of application tabs showing defined checkpoints with
their characteristics, e.g., ID, name of the checkpoint, number of places to be verified,
weight, execution time, and the role of the employee in the system (Figure 7, item 1), as
well as a description concerning the performance of control activities (Figure 7, item 2). It
is also possible to place photographic documentation here (Figure 7, item 3), assign picto-
grams as information indicators (Figure 7, item 4), and place instructions on how to pro-
ceed, e.g., in a PDF, MP3 or AVI file (Figure 7, item 5).
The system allows you to schedule TPM checks (pressure gauge, oil level, etc.) at the
right time. Figure 8 shows the functionality of the system in terms of scheduling inspec-
tions for a control point, which in this case is titled Tool holder control. Here, you can see
the control schedule based on a specific day of the week (Figure 8, item 1), as well as based
on a specific date (Figure 8, item 2).

Figure 8. A screenshot of the TPM application showing the scheduling of checks to be performed
Figure 8. A screenshot
for a of the TPM application showing the scheduling of checks to be performed for
checkpoint.
a checkpoint.
 Subsequently, the number of points to be assigned for the performance of the control ac-
tivity, their weight, and the time allocated to a given control point are visible (Figure 9,
item 3–5). There are also specialists assigned to a given checkpoint in terms of their role
(Figure 9, item 6) and there is also a place for a description of the operation (Figure 9, item
7). Next, icons are displayed as information indicators for the checkpoint (Figure 9, item
Appl. Sci. 2023, 13, 6259 10 of 16
8), instructions for download (Figure 9, item 9), and option buttons for details, icons, QR
codes, corrections, and checkpoint removal (Figure 9, item 10).

Figure 9. Screenshot of the TPM application showing an example list of checkpoints stored in the
Figure 9. Screenshot of the TPM application showing an example list of checkpoints stored in
system.
the system.
In
In turn,
turn, the
thelist
listofofscheduled
scheduledinspection
inspectionorders
ordersis is
shown
shownin Figure 10, 10,
in Figure including in-
including
spections
Appl. Sci. 2023, 13, x FOR PEER REVIEW to be assigned (Figure 10, item 1), those assigned (Figure 10, item 2), and
inspections to be assigned (Figure 10, item 1), those assigned (Figure 10, item 2), and other
12 other
of 18
(Figure
(Figure 10,
10, item
item 3),
3), e.g.,
e.g., completed and waiting
completed and waiting for
for confirmation
confirmation oror cancelled.
cancelled.

Figure 10. Screenshot of the TPM application showing an example list of scheduled checkpoints.
Figure 10. Screenshot of the TPM application showing an example list of scheduled checkpoints.

As
As already
alreadymentioned,
mentioned,the theTPM
TPM application
applicationcancan
be be
installed on company
installed on company mobile de-
mobile
vices of production employees and maintenance services. The operator or
devices of production employees and maintenance services. The operator or technician technician per-
forming
performing the the
machine
machineinspection scans
inspection scansthethe
QRQRcode
codeononthethemachine.
[Link]
Afterscanning
scanning thethe
code,
code, full instructions on what to do appear. Next, the controller scans the QR codes
full instructions on what to do appear. Next, the controller scans the QR codes of of
individual checkpoints and
individual checkpoints andassesses
assessesthe
thecompliance
compliance ofof
thethe actual
actual state
state withwith
the the instruc-
instructions.
tions. In addition,
In addition, they
they can cancomments
enter enter comments
into theinto the system.
system. Only
Only after after verification
verification is it
is it possible
possible to proceed to the next steps. Thanks to this, the employer can be sure
to proceed to the next steps. Thanks to this, the employer can be sure that all points defined that all
points defined in the inspection plan have been checked. This solution eliminates the need
to archive paper inspection plans, helping to maintain the technical efficiency of produc-
tion machines and devices and supervise ongoing activities.
The screenshot in Figure 11 shows an exemplary description of the control for a CNC
Appl. Sci. 2023, 13, 6259 11 of 16

in the inspection plan have been checked. This solution eliminates the need to archive
paper inspection plans, helping to maintain the technical efficiency of production machines
and devices and supervise ongoing activities.
The screenshot in Figure 11 shows an exemplary description of the control for a
CNC 63,770 machine tool. The panel contains basic data about the machine (Figure 11,
item 1). There are also photos of the machine taken from the front, rear, left, and right
sides (Figure 11, item 2). In addition, the panel contains important optional data (Figure 11,
item 3), such as parameters (production machine), checkpoints and instructions, definitions
Appl. Sci. 2023, 13, x FOR PEER REVIEW 13 of 18
(specifying when and how to control, what to control, and by whom), and orders (the
definition also includes the generation of orders).

Figure 11. Screenshot showing selected functionality of the e-Lean application—CNC Machine Tool
Figure 11. Screenshot showing selected functionality of the e-Lean application—CNC Machine Tool
63,770 overview.
63,770 overview.
The
The e-Lean
e-Lean application,
application, used used toto carry
carry out
out TPMTPM checks,
checks, hashas the
the functionality
functionality to to search
search
for
for reports
reports inin aa given
given period
periodof oftime
timeforforall
allworking
workingmachines
machines(Figure
(Figure 12,12,
itemitem1),1),
as as
wellwell
as
as reports for individual working machines (Figure 12, item 2). In
reports for individual working machines (Figure 12, item 2). In addition to the control result addition to the control
result expressed
expressed as a percentage
as a percentage of the
of the ratio of ratio
correct ofpoints
correcttopoints to all (positive
all (positive result above result above
50%), the
50%), the report result is presented numerically for individual control
report result is presented numerically for individual control points (CP). The first numerical points (CP). The
first
value, numerical value,
3, represents the3,number
represents the number
of points to check. of points to [Link]
The numerical The numerical
of 2 and 1values mean
of 2 and 1 mean
compatible pointscompatible points and points,
and non-consistent non-consistent points,
respectively respectively
(Figure 12, item(Figure 12, item
3). In addition,
3).
theIn addition,
e-Lean the e-Lean
application application
indicates indicates
the employee who the employee
performs thewho
controlperforms
activitythe control
(Figure 12,
activity (Figure 12, item 4) and defines the status of the control
item 4) and defines the status of the control result, its confirmation, and comments in the result, its confirmation,
and
event comments
of rejection in (Figure
the event 12,ofitem
rejection
5). (Figure 12, item 5).
Another
Another screenshot of the e-Lean application
screenshot of the e-Lean application shows shows aa list
list of
of machines
machines in in individual
individual
areas
areas ofof the
the enterprise
enterprise(Figure
(Figure13, 13,item
item1).1).InInthis
thispart
partofof
thethe application
application therethereis aispanel
a panel
for
for managing
managing production
production machines
machines (Figure
(Figure 13, item
13, item 2),itand
2), and it is possible
is possible to correct
to correct infor-
information
mation about machines
about machines by editing
by editing (Figure (Figure
13, item13, item
3) or 3) or deleting
deleting machines
machines (Figure
(Figure 13, 13,
itemitem
4),
4), as well as view statistical data (Figure 13, item 5) and TPM control
as well as view statistical data (Figure 13, item 5) and TPM control reports for individual reports for individ-
ual machines
machines (Figure
(Figure 13, item
13, item 6). 6).
 Sci. 2023,
Appl. Sci. 2023, 13, x6259
FOR PEER REVIEW 1412of
of 18
16

Appl. Sci. 2023, 13, x FOR PEER REVIEW 14 of 18

Figure 12. Screenshot of TPM reports in e-Lean.

Figure 12. Screenshot
Figure12. of TPM
Screenshot of TPM reports
reportsin
ine-Lean.
e-Lean.

Figure 13. Screenshot of the e-Lean application showing an overview of the company’s machines.
Figure
Figure 13. Screenshot
Screenshot of
of the e-Lean application showing an overview of the company’s machines.
In addition,
In addition, the application can be used as a motivator that encourages
that encourages employees to to
In addition, the application can be used as a motivator that encourages employees to
perform review activities because it contains a bonus system that grants a specific pool of
perform review activities because it contains a bonus system that grants a specific pool of
points for each activity, which the employer can include in the bonus process.
points for each activity, which the
the employer
employer can
can include
include in
in the
the bonus
bonus process.
process.
The TPM application was tested at Technonicol Insulation. After that, the first update
The TPM
The TPM application
application was tested
tested at
at Technonicol
Technonicol Insulation. After
After that,
that, the
the first
first update
update
to the application was carried out and preparation for implementation in automotive
to
to the application
application was carried out and preparation for implementation in automotive
plants was undertaken. The results of the implementation turned out to be very promising.
Appl. Sci. 2023, 13, 6259 13 of 16

Table 1 shows the averaged results from at least three measurements obtained during a TPM
inspection carried out on a production line in a construction company. The average control
time consisting of carrying out three control points (polymerization furnace, packing area,
and defibering machines) was reduced from 16,200 to 13,923 s. Thus, thanks to the use of
the application, the effectiveness of the TPM tool was increased by approx. 15% compared
to previously used non-digital solutions.

Table 1. The results of TPM inspections carried out for a production line in a construction company
using conventional and digital solutions.

TPM Control
Conventional E-Lean
Checkpoints
Time Time
Added Value Yes No Added Value Yes No
[s] [s]
System approval of System approval of
the control requires all the control requires all
— x x —
checkpoints to be checkpoints to be
passed passed
Direct access by Direct access by
superiors to control superiors to control
— x x —
activities and their activities and their
statutes statutes
Control photos of Control photos of
1st checkpoint—
machines placed in the machines placed in the
polymerization 900 — x 873 x —
system, with easy system, with easy
furnace
access access
Optimization of work Optimization of work
(optimal number of (optimal number of
steps taken by the — x steps taken by the x —
employee during the employee during the
inspection and time) inspection and time)
Efficient employee Efficient employee
motivation system — x motivation system x —
(collection of points) (collection of points)
System approval of System approval of
the control requires all the control requires all
— x x —
checkpoints to be checkpoints to be
passed passed
Direct access by Direct access by
superiors to control superiors to control
— x x —
activities and their activities and their
statutes statutes
Control photos of Control photos of
2nd checkpoint—
machines placed in the machines placed in the
packing 900 — x 810 x —
system, with easy system, with easy
area
access access
Optimization of work Optimization of work
(optimal number of (optimal number of
steps taken by the — x steps taken by the x —
employee during the employee during the
inspection and time) inspection and time)
Efficient employee Efficient employee
motivation system — x motivation system x —
(collection of points) (collection of points)
Appl. Sci. 2023, 13, 6259 14 of 16

Table 1. Cont.

TPM Control
Conventional E-Lean
Checkpoints
Time Time
Added Value Yes No Added Value Yes No
[s] [s]
System approval of System approval of
the control requires all the control requires all
— x x —
checkpoints to be checkpoints to be
passed passed
Direct access by Direct access by
superiors to control superiors to control
— x x —
activities and their activities and their
statutes statutes
Control photos of Control photos of
3rd checkpoint—
machines placed in the machines placed in the
defibering 14,400 — x 12,240 x —
system, with easy system, with easy
machines
access access
Optimization of work Optimization of work
(optimal number of (optimal number of
steps taken by the — x steps taken by the x —
employee during the employee during the
inspection and time) inspection and time)
Efficient employee Efficient employee
motivation system — x motivation system x —
(collection of points) (collection of points)
Total 16,200 13,923

In addition to the functionalities presented in Chapter 2 and 3, the e-Lean system has
additional functionalities that are added values and show the advantage of the e-Lean TPM
system over conventional TPM. This is reflected in the results in Table 1.
The next research step will be to analyze the possibility of implementing the appli-
cation at the stage of designing the production process in such a way that the machine
or device comes to the customer with the software. The software, based on the technical
and operational documentation, will have a defined inspection schedule prepared by the
machine manufacturer.

4. Conclusions
The digitization of TPM resulted in a significant increase in the functionality of the
tool and an improvement of 15% in its effectiveness based on the time of inspections carried
out. Reducing the time of inspections, however, is not the main aspect that causes interest
in lean digitization.
The most important element is the real possibility of monitoring the performed tasks,
consequently resulting in an increase in the effectiveness of the inspections (TPM) carried
out in this case and in turn allowing for the early detection of irregularities and the
possibility of planning preventive activities, thus eliminating the potential occurrence of
failures during production.
With conventional methods, it is not possible to reliably verify the performed work,
while digital methods force the user to go to specific places to enter the appropriate results
into the system to go to the next step and finally complete the activities related to daily
operator inspections (autonomous maintenance). Machine inspections become real, and
we have the ability to monitor them and evaluate their effectiveness based on reliable data.
The used methodology and respective tools that allowed the mentioned results to
be achieved can be extrapolated for similar cases in industry. This approach, as it is
Appl. Sci. 2023, 13, 6259 15 of 16

presented, is simple in terms of understanding and practical application for engineers in

their respective companies.

Author Contributions: Conceptualization, D.M., P.B., P.M., R.G., K.K., M.D., A.B. and Z.P.; method-
ology, D.M., P.B., K.K., A.B. and Z.P.; software, D.M., P.M., K.K., M.D. and Z.P.; validation, P.B.,
A.W., M.D. and J.M.; formal analysis, P.M. and A.W.; investigation, D.M., P.B., P.M., R.G. and K.K.;
resources, R.G., K.K., M.D. and A.B.; data curation, A.W., R.G. and K.K.; writing—original draft
preparation, D.M., P.B., P.M., A.W. and R.G.; writing—review and editing, D.M., M.D., A.B., Z.P. and
J.M.; visualization, A.W., R.G. and Z.P.; supervision, A.B., Z.P. and J.M.; project administration, A.B.
and J.M.; funding acquisition, P.B., P.M. and J.M. All authors have read and agreed to the published
version of the manuscript.
Funding: The authors are grateful to FCT (Fundação para a Ciência e Tecnologia, Portugal) who
partially financially supported this work through the RD Units Project Scope UIDP/04077/2020 and
UIDB/04077/2020.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Acknowledgments: The authors thank their respective institutions for all provided support.
Conflicts of Interest: The authors declare no conflict of interest.

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