A smart maintenance management transformation path: the Pirelli case study

The objective of this project is to demonstrate the improvements achievable in the maintenance management of the Pirelli plant through the application of practices and tools belonging to the Industry 4.0 family. The thesis primarily unfolds by exploring the theory related to Maintenance Management. It begins by presenting its foundational pillars and then delves into the theory of maintenance, including a mathematical perspective, introducing the Reliability Theory, and addressing the main maintenance standards that companies must adhere to (ISO 9001 and IATF 16949). The exploration continues by introducing four types of maintenance: Corrective, Preventive, Condition-based, and Predictive. The thesis then covers key strategies in the Maintenance world, including Reliability-Centered Maintenance, starting with its fundamental questions and concluding with its benefits; Total Productive Maintenance, beginning with the 8 pillars of TPM, its benefits, and the OEE indicator; and Smart Maintenance, emphasizing the domains of Industry 4.0 and Sensors. The theoretical part concludes with the analysis of some Maintenance KPIs (Availability, Reliability, and Maintainability Indicators) and presents the functions, implementation, and benefits of CMMS. The subsequent section focuses on the internship conducted at the Pirelli plant in Bollate (MI). It introduces the current situation (AS-IS), the actual project with the results achieved, and concludes with the future initiatives planned by the Maintenance Department. The results obtained affirm the path that European, especially Italian, companies must undertake. Through the adoption of preventive maintenance plans, it has been possible to reduce the MTTR and the downtime of the machinery in question, providing more available time for production.