A Novel Smart Production Management System for the Enhancement of Industrial Sustainability in Industry 4.0

Abstract

In industry 4.0, shop floor management teams are increasingly focused on developing an unprecedented strategy to avoid financial losses and address the challenges and problems encountered in operations management. In the present scenario, the management teams use various process optimization approaches for operational control, including lean manufacturing, smart manufacturing, the internet of things, and artificial intelligence. The process optimization approach is used to maximize productivity within limited constraints on the shop floor. The present research aims to develop a smart production management system and suggest an efficient process optimization approach to enhancing industrial sustainability by identifying problems and challenges encountered in the complex shop-floor conditions in industry 4.0. The developed production management system has been prepared by classifying the challenges and problems found in the previous research work and organizing brainstorming sessions. The developed management system has been validated by a comprehensive investigation of a case study of an earthmoving machinery manufacturing unit. The analysis showed that the developed system could enhance operation excellence and industrial sustainability in industry 4.0 by optimizing the utilization of resources on the shop floor within limited constraints. The authors of the present article strongly believe that the developed production management system will improve operational excellence and would be beneficial for industry personnel and researchers in controlling operations management in shop floor management of heavy machinery manufacturing, including industry 4.0.

Recent Progression Developments on Process Optimization Approach for Inherent Issues in Production Shop Floor Management for Industry 4.0

“…Various process optimization approaches are currently used, including lean manufacturing, kaizen, smart manufacturing, total quality management, and computational intelligence. These approaches are used to improve operational conditions by eliminating waste on the shop floor [25]. Industry individuals use several techniques to implement process optimization concepts on the shop floor, as shown in Figure 1.…”

“…It is a necessity of the industry to manufacture a product, keeping in mind the cost and quality of production. In reviewing previous research work, it has been found that the shop floor management team members face several problems in achieving operational excellence [25,46,57,69,84,93,145,180]. The problems were found in work planning, layout, higher downtime, ergonomics issues, and the working environment.…”

Analyzing critical factors of strategic alignment between operational excellence and Industry 4.0 technologies in smart manufacturing

“…OPEX is to manage the increasingly competitive environment and complexity today by using the right methods (Tripathi et al, 2022). OPEX is one of the business strategies, which is more consistently and reliably than the competition, with lower operational risk, operating costs and increased revenues compared to its competitors (Jengwa and Pellissier, 2022).…”

“…OPEX is to manage the increasingly competitive environment and complexity today by using the right methods (Tripathi et al. , 2022).…”

A Sustainable Productive Method for Enhancing Operational Excellence in Shop Floor Management for Industry 4.0 Using Hybrid Integration of Lean and Smart Manufacturing: An Ingenious Case Study

“…The lean and smart concept works as a booster in industry 4.0 and improves the decision-making ability of the industry individuals in terms of manpower and machinery. The objective of lean and smart is to develop a positive impact in all aspects of operational performance on the overall production shop floor [7]. The lean and smart concepts have been implemented to control production management by analyzing the real-time of operational activities.…”