A Systematic Improvement Model to Optimize Production Systems within Industry 4.0 Environments: A Simulation Case Study

Abstract

The industrial revolutions and their impact on production systems have increased productivity and quality in manufacturing over time. Lean methods have been the driver of the development of production systems from the 1990s to the rise of the fourth industrial revolution, or Industry 4.0. However, many different approaches and methodologies have been described, applied, and discussed for achieving improvements in production systems. As a result, organizations are often confused in regard to the order, the convenience, and the outcomes intended by the different improvement strategies and techniques. This paper provides a systematic sequence of process optimization steps that can be applied to any organization. A conceptual model was built based on the systematic sequence. In addition, a simulation model was built with the goal of representing and quantifying the sequential steps of the conceptual model. The results of the simulation model show a clear improvement in quality, performance, and economic indicators, with the first two steps in the optimization sequence providing critical initial information, while the three last steps served as net contributors to a global production system improvement for demanding market scenarios. Finally, we analyzed the impacts of Industry 4.0 on production systems and developed a methodological sequence to design, select, implement, and control projects, even those that include Industry 4.0 technologies.

Dynamic Innovation Information System (DIIS) for a New Management Age

“…A digital twin model and the link with information system databases are the basis for performing simulations that enable one to analyze policies based on what-if analysis and statistical techniques. Based on Figure 3, there are already digital twin models and simulations for the different functions within different types of organizations, such as procurement [47], distribution [45,48,49], production and quality [50], maintenance [51], information systems [52], sales [53], human resources [54][55][56], design, and development [57], for the planning and control of operations [52,58], for finance, improvement strategies, and strategic planning [59][60][61], as well as at the normative level [46]. Moreover, there are already models that can assess the three different levels, i.e., organization, supply chain, and related environment [51].…”

An assessment framework to evaluate the critical success factors to Quality 4.0 transition in developing countries: a case experience of sustainable performance of Indian manufacturers

“…Companies are able to improve efficiency and market share; better customer service helps company reputation, leading to future expansion. (Javaid et al, 2021); decrease in human errors (Antony et al, 2023a, b); optimum production performance (Groten and Gallego-Garc ıa, 2021); easier maintenance (Zonta et al, 2020) and time to market is reduced (Carvalho and Lima, 2022) (continued ) The authors develop the subsequent sections in the following manner. Section 2 introduces the theoretical framework employed in this study, while Section 3 outlines the methodology employed.…”

Development Trends of Production Systems through the Integration of Lean Management and Industry 4.0

“…On the other hand, over the past decades, the Lean management system has proven to comprise the most efficient methods and techniques of manufacturing organizations, with wide and successful applicability [16], especially in companies producing goods and services and in the processing and automotive industries. Current studies and research [17][18][19] assess "synergy", the connection between the two large concepts (i.e., Industry 4.0 and Lean management), and the possibility of correlating the demands imposed on modern manufacturing and integrating new management models. Winkler et al (2022) [20] holistically approached the development of production organizations from the perspective of integrating organizational management into Industry 4.0, making contributions through the integrated conceptual framework and simulation model, with applicability in increasing the performance of production systems.…”