Evolution of a Lean Smart Maintenance Maturity Model towards the new Age of Industry 4.0

Abstract

Over the last few years, the complexity of asset and maintenance management of industrial plants and machinery in the producing industry has risen due to higher competition and volatile environments. Smart factories, Internet of Things (IoT) and the underlying digitisation of a significant number of processes are changing the way we have to think and work in terms of asset management. Existing Lean Smart Maintenance (LSM) philosophy, which focuses on the cost-efficient (lean) and the learning organisation (smart) perspectives enables a value-oriented, dynamic, and smart maintenance/asset management. The associated LSM maturity model is the evaluation tool that contains the normative, strategic, and operational aspects of industrial asset management, based on which numerous reorganisation projects have already been carried out in industrial companies. However, due to the ever-increasing development of Industry 4.0 (I4.0), it is necessary to extend the model by selected aspects of digitisation and digitalisation. Based on a structured literature review (SLR) of state of the art I4.0 maturity models, we were able to investigate the essential maturity items for I4.0. To restructure and expand the existing LSM maturity model, the principle of design science research (DSR) was used. The architecture of the LSM maturity model was based on the structure of the Capability Maturity Model Integration (CMMI). Further development of a Lean Smart Maintenance maturity model thus covers the future requirements of I4.0 and data science. It was possible to enhance existing categories with new artefacts from the I4.0 range to represent the influence of cyber-physical systems (CPS), (big) data and information management, condition monitoring (CM) and more. Furthermore, the originally defined LSM-Model was restructured for a more simplified application in industrial use cases.