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.     

Industry 4.0: state of the art and future trends

Rapid advances in industrialisation and informatisation methods have spurred tremendous progress in developing the next generation of manufacturing technology. Today, we are on the cusp of the Fourth Industrial Revolution. In 2013, amongst one of 10 ‘Future Projects’ identified by the German government as part of its High-Tech Strategy 2020 Action Plan, the Industry 4.0 project is considered to be a major endeavour for Germany to establish itself as a leader of integrated industry. In 2014, China’s State Council unveiled their ten-year national plan, Made-in-China 2025, which was designed to transform China from the world’s workshop into a world manufacturing power. Made-in-China 2025 is an initiative to comprehensively upgrade China’s industry including the manufacturing sector. In Industry 4.0 and Made-in-China 2025, many applications require a combination of recently emerging new technologies, which is giving rise to the emergence of Industry 4.0. Such technologies originate from different disciplines including cyber-physical Systems, IoT, cloud computing, Industrial Integration, Enterprise Architecture, SOA, Business Process Management, Industrial Information Integration and others. At this present moment, the lack of powerful tools still poses a major obstacle for exploiting the full potential of Industry 4.0. In particular, formal methods and systems methods are crucial for realising Industry 4.0, which poses unique challenges. In this paper, we briefly survey the state of the art in the area of Industry 4.0 as it relates to industries.     

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.     

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.     

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.     

Industry 4.0 and resilience in the supply chain: a driver of capability enhancement or capability loss?

The purpose of this research is to develop a better understanding of smart systems and autonomous processes of the Industry 4.0 era. Does the implementation of Industry 4.0 processes and systems expose firms to higher levels of risk in the supply chain through capability loss or does Industry 4.0 spur capability enhancement and thereby increase supply chain resilience? Industry 4.0 is centred on the idea that certain tasks and decisions can be automated through smart systems and autonomous processes. However, is there a risk of losing critical capabilities and the ability to be flexible, agile and resilient to unexpected disruptions in the supply chain? In order to address these questions, this research presents results from semi-structured interviews across multiple industries to provide findings on firms’ uses of smart systems and capability development associated with these systems. Results from this exploratory study may be classified into two primary insights. First, although Industry 4.0 systems are new and, in many cases untested, firms are eager regarding the potential of smart systems to positively impact firm performance and to leverage Industry 4.0 processes for a competitive supply chain advantage. Second, companies did not claim any human capability loss associated with Industry 4.0. In fact, these smart systems may lead to increased supply chain resilience because of capability enhancement and new skill development.     

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.     

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.     

Cyber–Physical Production Systems for Data-Driven,Decentralized, and Secure Manufacturing—A Perspective

With the concepts of Industry 4.0 and smart manufacturing gaining popularity, there is a growing notion that conventional manufacturing will witness a transition toward a new paradigm, targeting innovation, automation, better response to customer needs, and intelligent systems. Within this context, this review focuses on the concept of cyber–physical production system (CPPS) and presents a holistic perspective on the role of the CPPS in three key and essential drivers of this transformation: data-driven manufacturing, decentralized manufacturing, and integrated blockchains for data security. The paper aims to connect these three aspects of smart manufacturing and proposes that through the application of data-driven modeling, CPPS will aid in transforming manufacturing to become more intuitive and automated. In turn, automated manufacturing will pave the way for the decentralization of manufacturing. Layering blockchain technologies on top of CPPS will ensure the reliability and security of data sharing and integration across decentralized systems. Each of these claims is supported by relevant case studies recently published in the literature and from the industry; a brief on existing challenges and the way forward is also provided.     

An analysis of the effect of a reliability paradigm shift on leading British aerospace companies

The aerospace industry is moving towards a new paradigm for the statement of reliability specifications. This paradigm is not a technical metric inherent to a system in isolation, but rather encompasses the wider objectives, operational profile and logistic priorities of its customer. This customer focus is encapsulated in the metrics Failure Free Operating Period and Maintenance Free Operating Period. These metrics describe the duration of effective system operation, in the first case for systems where faults and maintenance are permitted and in the second for systems where faults may not be repaired. As part of the Department of Trade and Industry (DTI) funded Aerospace Project for Insertion of Reliability (ASPIRE) research programme, which itself is part of the Ultra Reliable Aircraft (URA) programme, representatives of leading aerospace companies were interviewed about their opinion n how this new reliability paradigm and associated concepts would affect their way of doing business and their engineering processes. It would appear that the aerospace industry is ready for a move to a more realistic set of reliability metrics and away from the old style MTBF based metrics. This sea change would most likely be welcomed by customers, but as yet the manufacturing companies are unconvinced that such a radical move would be a good thing. Much of the resistance to change is due to old‐fashioned, but well entrenched, beliefs in the traditional way of doing things. A move away from this would bring freshness to the industry and lead to cost and time savings as the traditional approach is dropped in favour of a more planned and thought out approach. Copyright © 2002 John Wiley & Sons, Ltd.     

Human factors and ergonomics in manufacturing in the industry 4.0 context – A scoping review

Industry 4.0 revolution has brought rapid technological growth and development in manufacturing industries. Technological development enables efficient manufacturing processes and brings changes in human work, which may cause new threats to employee well-being and challenge their existing skills and knowledge. Human factors and ergonomics (HF/E) is a scientific discipline to optimize simultaneously overall system performance and human well-being in different work contexts. The aim of this scoping review is to describe the state-of-the-art of the HF/E research related to the industry 4.0 context in manufacturing. A systematic search found 336 research articles, of which 37 were analysed utilizing a human-centric work system framework presented in the HF/E literature. Challenges related to technological development were analysed in micro- and macroergonomics work system frameworks. Based on the review we frame characteristics of an organisation level maturity model to optimize overall sociotechnical work system performance in the context of rapid technological development in manufacturing industries.     

Industry 4.0 as an enabler of sustainability diffusion in supply chain: an analysis of influential strength of drivers in an emerging economy

Industry 4.0 (I4.0) and sustainability are recent buzzwords in manufacturing environments. However, the connection between these two concepts is less explored in the literature. In the current business context, the future generation of manufacturing systems is greatly influenced by the rapid advancement of information technology. Therefore, this study aims to examine the drivers of I4.0 to diffuse sustainability in Supply Chains (SCs). This research identifies the most relevant drivers through the literature and discusses them with area experts. Afterwards, an empirical analysis is conducted to validate the key drivers. Finally, the Grey based DEMATEL method is employed to examine the influential strength of the identified drivers and to build an interrelationship diagram. ‘Government supportive policies’ and ‘Collaboration and transparency among supply chain members’ were reported as highly significant drivers of I4.0. This study is an initial effort that investigates the key drivers of I4.0 to achieve high triple bottom line (ecological-economic-social) gains in SCs by taking an example from an emerging economy, i.e. India. This study may help managers, practitioners and policy makers interested in I4.0 applications to diffuse sustainability in SCs.     

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.     

On-line condition monitoring of servo motor drive systems by HHT in Industry 4.0

Abstract

Industry 4.0, the current trend of automation and data exchange in manufacturing technologies, includes the development of cyber-physical systems, the Internet of Things, and cloud computing, which create what has been called a ‘smart factory.’ In order to prevent digital manufacturing production lines in smart factories from shutting down, the development of self-diagnostic techniques is a significant issue in Industry 4.0. Thus, this paper presents a novel on-line condition monitoring method that is based on the measured line current of a brushless DC motor drive system. The characteristic component of line current is extracted by the time–frequency signal processing method, namely the ensemble empirical mode decomposition-based Hilbert Huang Transform (EEMD-based HHT), and then the mean value of characteristic component of current utilized for health monitoring is obtained. For the sake of increasing the reliability of the results, gauge repeatability and reproducibility is employed to evaluate the reliability of the computed mean value of the characteristic current. A healthy reference index, defined from the characteristic intrinsic mode function, is proposed for decision-making during on-line monitoring. Theoretical analysis and experiments are conducted to evaluate the effectiveness of the proposed health monitoring approach.     

Industry 4.0 integration with socio-technical systems theory: A systematic review and proposed theoretical model

Industry 4.0 promises the fourth industrial revolution by integration of cyber and physical worlds through technology. Industry 4.0 implementation will result in human interaction with technical system in a specialised manner. Therefore, Industry 4.0 will also be a socio (human related) and technical (nonhuman related) system in pursuit of a common goal. The purpose of this study is to suggest a mechanism to include Socio-Technical Systems Theory perspective while designing architecture for integration while implementing Industry 4.0. Building on the previous literatures on Socio-Technical Systems Theory and Industry 4.0, the article proposes bringing the two approaches together and presents a framework for integration mechanism. Successful implementation of Industry 4.0 warrants vertical, horizontal and end-to-end integration. This study suggests a design mechanism for three types of integration mechanism in Industry 4.0 by considering the socio-technical systems impact on people, infrastructure, technology, processes, culture and goals. Further, the integration is also suggested for analysis on the impact of stakeholders, economic situation and regulatory frameworks around which the operating organizations are operating. This is the first paper to propose the consideration of Socio-Technical Systems theory while designing the horizontal, vertical and end-to-end integration for sustainable implementation of Industry 4.0.     

Performance evaluation of an auction-based manufacturing system using coloured Petri nets

The next generation of manufacturing systems is assumed to be intelligent enough to make decisions and automatically adjust to variations in production demand, shop-floor breakdowns etc. Auction-based manufacturing is a control strategy in which various intelligent entities in the manufacturing system bid themselves, accept bids and make selections among the bids available based on a heuristic. This paper deals with the simulation modelling and performance evaluation of a push-type auction (negotiation) based manufacturing system embedded in a pulltype production system using coloured Petri nets. Three different models of an auction-based manufacturing system have been discussed. This methodology helps in developing systems for real-time control, anticipation of deadlocks, and evaluation of various performance metrics like machine utilization, automated guided vehicle (AGV) utilization, waiting times, work in process (WIP) etc. Various decision-making rules were identified for the real-time control of auction-based manufacturing systems.     

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.     

The link between Industry 4.0 and lean manufacturing: mapping current research and establishing a research agenda

In recent years, Industry 4.0 has emerged as one of the most discussed concepts and has gained significant popularity in both academia and the industrial sector. Both Industry 4.0 and lean manufacturing utilise decentralised control and aim to increase productivity and flexibility. However, there have been few studies investigating the link between these two domains. This article explores this novel area and maps the current literature. This is achieved through a systematic literature review methodology, investigating literature published up to and including August 2017. This article identifies four main research streams concerning the link between Industry 4.0 and lean manufacturing, and a research agenda for future studies is proposed.     

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.     

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.