TPM 4.0: How to Digitalise Maintenance with INEXION MES

In the era of industrial digitalization, maintenance has become a strategic factor in ensuring operational efficiency and production continuity.

Total Productive Maintenance (TPM), the basis of operational excellence for decades, is now evolving into a new phase: TPM 4.0, where technology, data and automation converge to create smarter, more efficient and sustainable plants.

With MES INEXION, Overtel offers a solution designed to bring industrial TPM into the digital age: connecting people, equipment and processes in a single environment of traceability and continuous improvement.

What is TPM 4.0, and how has industrial maintenance evolved?

From traditional TPM to connected maintenance

TPM (Total Productive Maintenance) was born in Japan in the 1970s with a clear objective: to eliminate breakdowns, downtime and defects in industrial plants. Its essence is still valid, but its approach has changed radically.

TPM 4.0 combines traditional methodology with digital technologies such as MES systems, IoT, advanced analytics and predictive maintenance, making it possible to move from reaction to anticipation.

Today, maintenance is no longer limited to repairing machines: it is an intelligent system that prevents failures, optimises resources and improves productivity in real time.

How Industry 4.0 redefines the role of the operator and of data

In Industry 4.0, data is the new production resource. Each machine generates valuable information about its performance, consumption or operational status.

Thanks to platforms such as MES INEXION, in many companies operators are no longer simple executors but digital maintenance managers, able to interpret alarms, monitor OEE indicators and act on production with accurate and contextualised data.

The digitisation of TPM: from paper to real-time data

Limitations of classic TPM

In many industrial environments, maintenance still relies on manual check sheets or scattered records. This makes it difficult to measure OEE (Overall Equipment Effectiveness) or to detect failure patterns.

The result: reactive decisions, downtime and unnecessary costs.

Digital Twins, IoT and MES as productive maintenance accelerators

With the adoption of digital TPM, factories integrate data from IoT sensors, digital twins and MES platforms to create a connected environment.

• Digital Twins simulate real machine behaviour.
• IoT sensors record temperature, vibration and consumption.
• The MES INEXION system centralises that information, analyses patterns and generates early warnings.

The result: predictive and traceable maintenance, capable of reducing unplanned downtime by up to 30%.

How INEXION MES empowers Total Productive Maintenance

Automatic data collection and early fault detection

INEXION MES/MOM automatically collects plant data in real time, from sensors, PLCs or SCADA, allowing you to identify performance deviations, micro-stops or anomalies without manual intervention.

In sectors such as food, pharmaceutical or automotive, this total visibility translates into a drastic reduction of downtime and better control of plant traceability.

OEE monitoring and availability metrics

OEE is at the heart of modern TPM. With our MES/MOM INEXION system, each indicator (availability, performance and quality) is automatically calculated, providing visual dashboards and customizable reports.

This allows operations managers to detect bottlenecks, prioritise maintenance and evaluate the real impact of each intervention.

Real-time communication between operators, maintenance and production

One of the keys to TPM 4.0 is collaboration. Our MES connects maintenance and production teams under the same platform, ensuring seamless communication between operators, technicians and engineers. Incidents are instantly reported and documented, with full traceability of cause, corrective action and outcome.

Benefits of digital TPM with MES INEXION

Operational efficiency and downtime reduction

By eliminating manual logging and automating data collection, plants can reduce downtime by up to 25%, improving overall equipment availability.

Predictive maintenance based on real data

INEXION MES's advanced analytics allow you to anticipate failures by analysing trends, temperature or vibration.

This enables proactive maintenance planning, avoiding costly breakdowns and extending asset life.

Continuous improvement culture supported by analytics

TPM 4.0 is not just technology: it is a culture of continuous improvement. INEXION's reports and dashboards facilitate data-driven decision making, driving more efficient management aligned with Lean principles.

Case study: how a factory can digitise its TPM step-by-step

MES integration with ERP and plant systems

The first step towards a digital TPM system is to integrate INEXION MES with corporate ERP and plant systems (PLC, SCADA or IoT). This connection allows linking production with maintenance planning and management, ensuring full traceability from order to final product.

Key success indicators: OEE, MTBF, MTTR

With INEXION, factories can measure in real time OEE, MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair). These indicators are essential to identify losses, prioritise actions and measure the impact of TPM 4.0 on overall productivity.

Expected results after 6 months of implementation

Industrial companies that have adopted MES systems for their TPM report:

• 30-40 % reduction in unplanned failures.
• 15-20 % increase in OEE.
• Energy savings of 10% by optimizing machine usage and downtime.

Sectors such as automotive, textile or food already apply these models with measurable results in efficiency and sustainability.

TPM 4.0 and industrial sustainability

Reducing waste and energy consumption

Digital predictive maintenance reduces material waste, time and energy. INEXION MES can identify anomalous consumption patterns and automatically adjust processes, aligning TPM with the goals of the green industry and the circular economy.

Responsible maintenance and resource control

The digitisation of TPM contributes directly to ESG (Environmental, Social, Governance) objectives, ensuring more sustainable, traceable and auditable processes.

TPM 4.0 represents the perfect union between the Japanese philosophy of total productive maintenance and digital technology applied to industrial efficiency. With INEXION MES, companies can transform their operations, achieve full traceability and make real-time, data-driven decisions.

Request a personalised demo and take your TPM to the next level.