Optimization of OEE and Energy Efficiency in Glass Manufacturing Using an Energy-Centric TPM Framework

Abstract

Achieving equipment efficiency improvements without significant increases in energy consumption is crucial in the continuous glass industry, one of the most energy-intensive and thermally constrained industries. While Total Productive Maintenance (TPM) and Total Equipment Efficiency (OEE) are widely used to reduce losses, energy efficiency is often viewed as an external cost rather than an operational variable, creating a gap between equipment efficiency and energy intensity. This paper proposes a global TPM framework focused on energy in continuous glass production, integrating: (1) real-time remote energy measurement, (2) contextual realistic outcomes mechanism (CMO) logic, (3) qualitative comparative fuzzy ensembles analysis (fsQCA), and (4) dynamic interaction modeling between total equipment efficiency and energy. This framework identifies alternative Total Productive Maintenance (TPM) configurations linked to sustainable improvements in Total Equipment Effectiveness (OEE). It models the temporal correlation between downtime, production line speed, quality loss, and specific energy consumption, and generates optimal trade-offs based on Pareto principle between OEE and energy per unit of output to support management decision-making. This proposed approach promotes energy-sensitive maintenance governance within the context of the Fourth Industrial Revolution and provides a model applicable to continuous, energy-intensive processes.