In recent years, there has been an increase in the adoption of quality tools by companies. As such, there has been a commitment to innovation by the organizations to obtain competitive advantages by the development of new products and technologies focused on the creation of economic value but also on delivering sustainability. This study aims to develop an application model of the inventive resolution theory in conjunction with the Eco-Compass ecological innovation tool, in order to allow solutions to be obtained systematically, and to present a performance increase of certain environmental parameters, promoting thus sustainable innovation. The case study research methodology is used to frame the research. The company under study is Nokia enterprise, located in Portugal, which offers a set of services related to telecommunications infrastructures. The unit of analysis is the department of transformation and continuous improvement, and the study illustrated the application of combined use of theory of inventive problem solving (TRIZ) and Eco-compass to develop innovative solutions systematically. The results show that it is possible to achieve innovation according to a certain level of established sustainable environmental parameters, while at the same time solving the identified inventive problem.

As the global market becomes increasingly competitive and demanding, companies face the challenge of responding swiftly and efficiently to customer needs. To maintain a competitive advantage, organisations must optimise the usage of their assets. This study focuses on the critical role of maintenance management and presents a novel, cost-effective, and easily applicable model that integrates Industry 4.0 (I4.0) and Total Productive Maintenance (TPM) principles to enhance production processes. The proposed model incorporates a real-time monitoring system equipped with sensors, a gateway, and Internet of Things (IoT) services. These components enable data acquisition, transmission, storage, and visualisation through both mobile and fixed devices. The model’s effectiveness was validated through its implementation on a conveyor belt in a feed mill. The availability of the conveyor belt was around 89.5% before TPM implementation. After the implementation of TPM, it was possible to observe that the availability of the treadmill increased to 92.7% in a workweek of 105 h. On the other hand, it was possible to observe a considerable improvement in terms of the average time of each intervention, with a reduction of around 53%. Moreover, the model also facilitated improvements in the maintenance plan for the conveyor belt. Operators were trained to effortlessly comply with the new autonomous maintenance plan, enhancing operational efficiency. The joint application of I4.0 and TPM demonstrated significant advancements in maintenance management. The flexibility of the developed model allows for easy adaptation to monitor other condition parameters, enabling real-time decision-making for both the maintenance and production departments. This integrated approach holds the potential to drive process optimisation, ultimately contributing to improved productivity, cost-effectiveness, and competitiveness.

Companies actively seek innovative tools and methodologies to enhance operations and meet customer demands. Maintenance plays a crucial role in achieving such objectives. This study identifies existing models that combine Lean Philosophy and Industry 4.0 principles to enhance decision-making and activities related to maintenance management. A comprehensive literature review on key concepts of Lean Philosophy and Industry 4.0, as well as an in-depth analysis of existing models that integrate these principles, is performed. An innovative model based on the synergies between Lean Philosophy and Industry 4.0, named the Maintenance Management in Sustainable Operations (MMSO) model, is proposed. A pilot test of the application of the MMSO model on a conveyor belt led to an operational time increase from 82.3% to 87.7%, indicating a notable 6.6% improvement. The MMSO model significantly enhanced maintenance management, facilitating the collection, processing, and visualization of data via internet-connected devices. Through this integration, various benefits are achieved, including improved flexibility, efficiency, and effectiveness in addressing market needs. This study highlights the value of integrating Lean Philosophy and Industry 4.0 principles to improve maintenance management practices. The proposed MMSO model effectively leverages these principles, fostering agility, optimized resource utilization, heightened productivity and quality, and reduced energy consumption. The model not only serves as a tool for operational optimization and customer demand enhancement but also aligns with sustainability principles within the energy transition. Its successful application in the pilot test phase further reinforces its potential as a reliable approach for maintenance management and sustainable operations in both production and decision-making processes.