Industry 4.0: Architecture and Equipment Revolution

The development of science and technology has led to the era of Industry 4.0. The core concept is the combination of “material and informationization”. In the supply chain and manufacturing process, the “material” of the physical entity world is realized by data, identity, intelligence, and information. Industry 4.0 is a disruptive transformation and upgrade of intelligent industrialization based on the Internet-of-Things and Big Data in traditional industrialization. The goal is “maximizing production efficiency, minimizing production costs, and maximizing the individual needs of human beings for products and services.” Achieving this goal will surely bring about a major leap in the history of the industry, which will lead to the “Fourth Industrial Revolution.” This paper presents a detailed discussion of industrial big data, strategic roles, architectures, characteristics, and four types of innovative business models that can generate profits for enterprises. The key revolutionary aspect of Industry 4.0 is explained, which is the equipment revolution. Six important attributes of equipment are explained under the Industry 4.0 perspective.     

工业4.0视角下工业设计对制造业转型升级的作用

目的研究工业4.0视角下工业设计对我国制造业转型升级的作用。方法首先简单分析了工业4.0对工业设计的影响,然后分别从国内和国外两个角度说明了我国制造业转型升级压力与动力并存,最后,重点对企业如何利用工业4.0环境下的发展条件,通过工业设计,实现企业转型升级进行了分析。结论工业4.0时代,工业设计通过促进企业产品升级、技术升级、产业结构升级、功能升级来总体实现我国制造业的转型升级。     

Designing lean value streams in the fourth industrial revolution era: proposition of technology-integrated guidelines

Despite the envisioned interrelations, the way Industry 4.0 (I4.0) technologies can influence the design and implementation of lean value streams is still unknown and little empirical evidence is found in the literature. This article aims at proposing guidelines integrated with I4.0 technologies for designing lean value streams. We gathered experts’ opinions regarding the relationship between guidelines for designing a lean value stream and I4.0 technologies. The identification of the most important relationships provided arguments for the proposition of enhanced guidelines for designing lean value streams within the Fourth Industrial Revolution context. The integration of I4.0 technologies into the guidelines for designing a lean value stream raises a distinct approach that benefits from the simplicity and efficiency of Lean Production with ease and agility of the technologies typical of the Fourth Industrial Revolution. Such technology-integrated guidelines may allow overcoming existing barriers while lead companies to superior performance results.     

Impacts of Industry 4.0 technologies on Lean principles

Industry 4.0 is increasingly being promoted as the key to improving productivity, promoting economic growth and ensuring the sustainability of manufacturing companies. On the other hand, many companies have already partially or fully implemented principles and tools from the Lean management approach, which is also aimed at improving productivity. While the two approaches use very different strategies, they share some common principles. The objective of this article is to highlight the links between the principles and tools proposed by Industry 4.0 and those proposed by the Lean management approach, with a particular focus on how some of Industry 4.0's technologies are improving the implementation of Lean principles, depending on the technologies’ capability levels. As such, this study aims to provide a characterisation of the impacts of Industry 4.0 technologies on Lean principles according to targeted capability levels. The results obtained show strong support for Industry 4.0 technologies for Just-in-time and Jidoka, but little or no support for waste reduction and People and Team work. There is, therefore, a clear need to pursue the deployment of Lean management while improving certain Lean principles using Industry 4.0 technologies.     

An empirical study for smart production for TFT-LCD to empower Industry 3.5

Abstract

With increasing technological advancements, manufacturing intelligence has become a crucial issue for maintaining competitive advantages. Industry 4.0, proposed by Germany, is one of the large-scale projects to achieve manufacturing intelligence and smart production. Others include the Advanced Manufacturing Partnership 2.0 (AMP2.0) from the United States, Industry 4.1J of Japan and Made in China 2025. On the other hand, most of the emerging countries may not be ready for the migration of Industry 4.0 directly since their industrial infrastructures are different with the leading countries. This study aims to propose Industry 3.5 as a hybrid strategy between existing Industry 3.0 and to-be Industry 4.0, in which digital decision-making, big data analytics, and manufacturing intelligence are integrated to empower smart production with disruptive innovations that can be realized in existing industrial infrastructure. To estimate the validity of the proposed Industry 3.5, an empirical study was conducted in a thin film transistor liquid crystal display (TFT-LCD) manufacturing factory in Taiwan. A smart daily planning and scheduling (DPS) system is developed to enhance manufacturing intelligence for smart production without a fully automation facility as the Cyber-Physical System proposed in Industry 4.0. This study concludes with discussions of development directions for industrial revolution.     

Integrated and Intelligent Manufacturing: Perspectives and Enablers

With ever-increasing market competition and advances in technology, more and more countries are prioritizing advanced manufacturing technology as their top priority for economic growth. Germany announced the Industry 4.0 strategy in 2013. The US government launched the Advanced Manufacturing Partnership (AMP) in 2011 and the National Network for Manufacturing Innovation (NNMI) in 2014. Most recently, the Manufacturing USA initiative was officially rolled out to further “leverage existing resources... to nurture manufacturing innovation and accelerate commercialization” by fostering close collaboration between industry, academia, and government partners. In 2015, the Chinese government officially published a 10-year plan and roadmap toward manufacturing: Made in China 2025. In all these national initiatives, the core technology development and implementation is in the area of advanced manufacturing systems. A new manufacturing paradigm is emerging, which can be characterized by two unique features: integrated manufacturing and intelligent manufacturing. This trend is in line with the progress of industrial revolutions, in which higher efficiency in production systems is being continuously pursued. To this end, 10 major technologies can be identified for the new manufacturing paradigm. This paper describes the rationales and needs for integrated and intelligent manufacturing (i²M) systems. Related technologies from different fields are also described. In particular, key technological enablers, such as the Internet of Things and Services (IoTS), cyber-physical systems (CPSs), and cloud computing are discussed. Challenges are addressed with applications that are based on commercially available platforms such as General Electric (GE)’s Predix and PTC’s ThingWorx.     

Intelligent Manufacturing in the Context of Industry 4.0: A Review

Our next generation of industry—Industry 4.0—holds the promise of increased flexibility in manufacturing, along with mass customization, better quality, and improved productivity. It thus enables companies to cope with the challenges of producing increasingly individualized products with a short lead-time to market and higher quality. Intelligent manufacturing plays an important role in Industry 4.0. Typical resources are converted into intelligent objects so that they are able to sense, act, and behave within a smart environment. In order to fully understand intelligent manufacturing in the context of Industry 4.0, this paper provides a comprehensive review of associated topics such as intelligent manufacturing, Internet of Things (IoT)-enabled manufacturing, and cloud manufacturing. Similarities and differences in these topics are highlighted based on our analysis. We also review key technologies such as the IoT, cyber-physical systems (CPSs), cloud computing, big data analytics (BDA), and information and communications technology (ICT) that are used to enable intelligent manufacturing. Next, we describe worldwide movements in intelligent manufacturing, including governmental strategic plans from different countries and strategic plans from major international companies in the European Union, United States, Japan, and China. Finally, we present current challenges and future research directions. The concepts discussed in this paper will spark new ideas in the effort to realize the much-anticipated Fourth Industrial Revolution.     

Scopus scientific mapping production in industry 4.0 (2011–2018): a bibliometric analysis

Research in industry 4.0 is growing, driven by the innovations in production systems on a continuous basis. In this study, we identified the evolution of themes inherent in the industry 4.0 using a bibliometric software, namely SciMAT (Science Mapping Analysis Software Tool). The analyses included 1882 documents, 4231 keywords, and the relevant information was extracted based on frequency of co-occurrence of keywords. The clusters were plotted in two-dimensional strategic diagrams and analysed using the bibliometric indicators such as the number of publications, number of associated documents, and h-index. The results revealed that 2017 had the largest number of publications. Expert authors in the field and the periodicals that published the most were identified. The science mapping presented 31 clusters in which the most representative motor themes were CPS (Cyber-Physical System), IoT (Internet of Things), and Big Data. In addition, it was possible to identify fields with high investment of efforts by the scientific community such as the union between lean production and industry 4.0, production-centered CPS (CPPS), IoT (Industrial Internet of Things - IIoT), among others. The overlapping map showed an increase in the number of keywords from 338 to 1231 over the period of data. The map of scientific developments supported by an exhaustive research, it was possible to show the state of the art, the main challenges and perspectives for future research in the field of industry 4.0 such as Technology, Collaboration/Integration, Management and Implementation.     

工业4.0对中国航空工业的影响探讨

以德国工业4.0为代表的第四次工业革命,对我国工业的发展产生了深远影响.本文首先分析了相关技术的发展趋势,以及此次变革的特征和要求,并总结分析了其在我国的发展现状,在此基础上重点分析了当前世界航空工业的技术现状,以及以信息化、数字化技术为代表的相关技术对航空工业产生的影响,我国航空工业在变革中标准顶层体系架构需要开展的工作.指出当今世界航空工业的发展技术水平应处在工业3.X的水平,我国航空工业处在工业2.X的水平,并对当前航空工业在变革中的发展给出了一些行动思路.     

The relevance of Industry 4.0 and its relationship with moving manufacturing out,back and staying at home

In view of the fact that Industry 4.0 is becoming increasingly essential, the implementation of Industry 4.0 technologies is believed to be an essential strategic component in further increasing the efficiency of manufacturing processes and in determining decisions concerning globalisation strategies. Thus, this paper provides an empirical analysis of the essential constructs of Industry 4.0, and drivers and barriers for Industry 4.0. The paper is based on 270 valid answers to a questionnaire-survey distributed among Danish manufacturers. Regression analyses were used to test the proposed hypotheses. The results of the analyses reveal that the identified drivers and barriers for Industry 4.0 have a positive impact on the perceived relevance of Industry 4.0 among companies. Furthermore, the analyses show that the perceived relevance of Industry 4.0 among companies has a positive impact on companies that have moved manufacturing back and on companies that have moved manufacturing out and back. Conversely, the perceived relevance of Industry 4.0 among companies has a negative impact on companies that have remained domestic. The perceived relevance of Industry 4.0 has no impact on companies that have moved manufacturing out. This research, in general, offers to both researchers and practitioners an increased consciousness concerning the relevant drivers and barriers for Industry 4.0 in decision processes about where to locate manufacturing.     

Identification of critical success factors,risks and opportunities of Industry 4.0 in SMEs

SMEs, as prominent actors in industry, must meet more and more complex customer expectations. Recently, the concept of Industry 4.0 has emerged. This new approach enables the control of production processes by providing real-time synchronisation of flows and by enabling the production of unitary and customised products. Our research goal is to identify Industry 4.0 risks, opportunities and critical success factors with regards to the industrial performance of SMEs. The recent emergence of Industry 4.0 and the inherent difficulty of identifying detailed examples has not yet enabled a satisfactory statistical study to be conducted on Industry 4.0 cases in SMEs. To reach our research goal, we selected 12 experts to conduct a Delphi study supplemented by Régnier’s abacuses. Our study demonstrates that the major risks facing the adoption of Industry 4.0 in SMEs include a lack of expertise and a short-term strategy mindset. Our research also indicates that training is the most important factor for success, that managers have a prominent role in the success and/or failure of an Industry 4.0 project, and that SMEs should be supported by external experts. Lastly, Industry 4.0 offers a unique opportunity to redesign SME production processes and to adopt new business models.     

Implementation of Industry 4.0 and lean production in Brazilian manufacturing companies

The adoption of Industry 4.0 technologies has been deemed as a strategy to increase product quality and make manufacturing processes more efficient. However, the way that these technologies are integrated into existing production systems and which processes they can support is still under investigation. Thus, this paper aims to examine the relationship between lean production (LP) practices and the implementation of Industry 4.0 in Brazilian manufacturing companies. To achieve that we use data from a survey carried out with 110 companies of different sizes and sectors, at different stages of LP implementation. Data collected were analysed by means of multivariate analysis. Our findings indicate that LP practices are positively associated with Industry 4.0 technologies and their concurrent implementation leads to larger performance improvements. Further, the contextual variables investigated do matter to this association, although not all aspects matter to the same extent and effect.     

Sustainable manufacturing in Industry 4.0: an emerging research agenda

This systematic review intends to identify how sustainable manufacturing research is contributing to the development of the Industry 4.0 agenda and for a broader understanding about the links between the Industry 4.0 and Sustainable Manufacturing by mapping and summarising existing research efforts, identifying research agendas, as well as gaps and opportunities for research development. A conceptual framework formed by the principles and technological pillars of Industry 4.0, sustainable manufacturing scope, opportunities previously identified, and sustainability dimensions, guided analysis of 35 papers from 2008–2018, selected by a systematic approach. Bibliometrics data and social network analysis complement results identifying how research is being organised and its respective research agendas, relevant publications, and status of the research lifecycle. Results point to that the current research is aligned with the goals defined by different national industrial programs. There are, however, research gaps and opportunities for field development, becoming more mature and having a significant contribution to fully developing the agenda of Industry 4.0.     

The Future of Manufacturing: A New Perspective

Many articles have been published on intelligent manufacturing, most of which focus on hardware, software, additive manufacturing, robotics, the Internet of Things, and Industry 4.0. This paper provides a different perspective by examining relevant challenges and providing examples of some less-talked-about yet essential topics, such as hybrid systems, redefining advanced manufacturing, basic building blocks of new manufacturing, ecosystem readiness, and technology scalability. The first major challenge is to (re-)define what the manufacturing of the future will be, if we wish to: ① raise public awareness of new manufacturing’s economic and societal impacts, and ② garner the unequivocal support of policy-makers. The second major challenge is to recognize that manufacturing in the future will consist of systems of hybrid systems of human and robotic operators; additive and subtractive processes; metal and composite materials; and cyber and physical systems. Therefore, studying the interfaces between constituencies and standards becomes important and essential. The third challenge is to develop a common framework in which the technology, manufacturing business case, and ecosystem readiness can be evaluated concurrently in order to shorten the time it takes for products to reach customers. Integral to this is having accepted measures of “scalability” of non-information technologies. The last, but not least, challenge is to examine successful modalities of industry–academia–government collaborations through public–private partnerships. This article discusses these challenges in detail.     

Determinants of information and digital technology implementation for smart manufacturing

This study aims to identify and analyse factors that determine the implementation of Information and Digital Technologies (IDT) of smart manufacturing. By performing a state-of-the-art and content-driven review of literature, consulting a group of experts from academia and industry, and implementing interpretive structural modelling methodology, the study identified eleven enabling factors and mapped the contextual interrelationships among them. The study further explained the complex precedence relationships that exist among determinants of smart manufacturing IDT adoption. Results showed that perceived benefits and management support are the two driver determinants that act as stepping-stones in the implementation of smart manufacturing IDT. Operations technology maturity and cybersecurity maturity were found to be the dependent determinants of smart manufacturing IDT implementation and highly driven by the linkage and driver determinates. The findings are expected to assist academicians, industrialists, and the policymakers with achieving a detailed understanding of smart manufacturing transformation processes, and conditions that facilitate the manufacturing digitalisation in the Industry 4.0 era.     

Industry 4.0: Current practice and challenges in Malaysian manufacturing firms

This research employed a qualitative approach to discuss the current practice and challenges of Malaysian manufacturing firms in the implementation of Industry 4.0. The study examined data from seven manufacturing companies pursuing Industry 4.0 initiatives to identify various options for their strategies. The study found that the implementation of Industry 4.0 in the manufacturing firms is still in the exploratory stage. The companies involved in this study were discovered to conduct exploration using an adaptive-like framework. That is, throughout the process, the majority of the subjects are 'trying and adding' Industry 4.0 to their operations. Their trial-and-error approach is based on what is feasible and effective in their manufacturing environment. Overall, the investigation determined that data management and integration, as well as personnel re-education, were the respondents' primary operational challenges.     

Towards a lean automation interface for workstations

Methods and principles of Lean Production have become the major concepts to create highly efficient processes since the early 1990s. Due to its high effectiveness by reducing complexity and focusing on value-adding tasks, the Lean concept is still successful. Nevertheless, its changeability to produce highly customised products is limited. Industry 4.0 describes the vision of a smart production which can meet these future market requirements. Enablers are innovative information and communication technologies and the integration of all production entities into a common digital network. Lean Automation is the application of Industry 4.0 technologies to Lean Production methods in order to combine benefits from both domains. First proprietary Lean Automation solutions exist, but to enhance changeability in production, a common, unified communication interface is required. This paper presents the ongoing work towards an interface for digitising Lean Production methods using Cyber Physical Systems.     

Modelling and quantification of industry 4.0 manufacturing complexity based on information theory: a robotics case study

The new industrial revolution called Industry 4.0 imposes new challenges to the research community. One of the main issues in Industry 4.0 is the management of the huge amount of information exchanged among its different integrated systems. The present work demonstrates how the traditional manufacturing system is transformed to the Industry 4.0 manufacturing system and proposes a modelling and quantification approach, which includes metrics from the Information Theory estimating the complexity and the capacity of the Industry 4.0, from the perspective of the communication among the systems. The application impact of the proposed Industry 4.0 system and the comparison of these metrics before and after shifting to Industry 4.0 is also analysed and validated in a case study from the Robotics Industry.     

“Nothing new under the sun”; do we need new searching protocols to establish the patentability of industry 4.0 inventions?

Efficient patentability searching demands that the searcher has the ability to identify efficiently the best sources of likely prior art for each invention being searched. This applies both within industry, at the point of drafting a patent application, and within patent offices conducting searches to support substantive examination. Industry 4.0 inventions are characterised by a particular nature and combination of technologies, notably the inclusion of aspects of Information and Communication Technologies (ICT). The default information sources currently used to establish patentability of ‘conventional’ inventions may be inappropriate for this new class of invention. This is partly due to the different structures of publication and methods of dissemination of research results found within computer science professions. It is suggested that searching in the secondary or tertiary literature may be a more fruitful approach to establish patentability in these areas of technology. However, expertise in the use of these types of source has been substantially lost, as the information industry has concentrated on production of full-text primary sources. Database production, database usage and search protocols all need to be reassessed if they are to meet the challenges of searching Industry 4.0 inventions.     

An empirical examination of benefits,challenges, and critical success factors of industry 4.0 in manufacturing and service sector

Industry 4.0 marks a new paradigm and has expanded its domain from theoretical concepts to real-world applications. Industry 4.0 is, however, still in the state of infancy and conceptual state wherein it is not clear as to how to incorporate many dynamic technological concepts in different sectors. Previous studies have conceptually delineated the benefits, challenges, and CSFs of Industry 4.0, however, there is yet to be an empirical study that critically examines the differences in benefits, challenges, and critical success factors (CSFs) of Industry 4.0 in both manufacturing and service industries and rank them. This study through an online survey captures the view of senior management professionals who have experience in Industry 4.0 implementation in major companies in Asia, Europe, and North America. 96 senior management professionals participated in this study through an online survey. The qualitative data on benefits and challenges were analysed using thematic analyses. The quantitative data on critical success factors were ranked using the normalisation of the mean to find the most important factors. Further agreement analysis was conducted in the manufacturing and service sectors for the CSFs. This study identifies the top five benefits and challenges in the manufacturing and service industries. The CSFs for Industry 4.0 was put forward and ranked in both the manufacturing and service industries.