Machine Tool Transition from Industry 3.0 to 4.0: A Comparison between Old Machine Retrofitting and the Purchase of New Machines from a Triple Bottom Line Perspective

Abstract

The emerging scenario designed by digital technologies connected to Industry 4.0 is pushing towards increasingly sustainable companies. Access to the multiple benefits of digitalization (such as increased productivity, flexibility, efficiency, quality, lower consumption of resources, and the improvement of worker safety) is possible by purchasing new-generation machinery. However, thanks to smart retrofitting processes, companies can extend the shelf life of machinery without replacing it entirely. This work aims to present a framework to assess the sustainability of implementing a smart retrofitting process in old machines as an alternative to replacement from a triple bottom line (economic, environmental, and social) perspective. Due to the multidimensional and multidisciplinary variables that the proposed framework must consider, a multicriteria decision-making process is developed to identify the best transition solution from Industry 3.0 to 4.0. Then, we analyze a case study in which, thanks to the previously proposed methodology, two types of smart retrofitting on a column drill are compared with three replacement options for the same machine tool. In conclusion, the case study shows that retrofitting in the context of Industry 4.0 (or smart retrofitting), despite its high acquisition cost, is the best solution in terms of sustainability, and that this is because the smart retrofitting solution not only positively influences all parameters of digitization but also has a strong impact on the safety criterion.

Retrofitting-Based Development of Brownfield Industry 4.0 and Industry 5.0 Solutions

“…The ultimate goal of a retrofitting project is the comprehensive digital transformation of legacy systems [14]. This successful transformation requires the development of costeffective and reliable measurement, along with data collection and manipulation solutions that can ensure condition monitoring [64]. The establishment of vertical and horizontal integration of the entire production is needed [65], to allow the autonomous operation of the equipment without significant modification [66].…”

“…Metal machining [64] Employ new actuators to extend the capability of existing hardware Serve as end actuator to an robotic arm.…”

“…In other cases, retrofitting effort is done with new sensors and actuators deployed [100]. Additional actuators can perform controlling on process variables automatically in a real-time manner [64], with the signal being monitored by respective sensor readings, or governed by an embedded board that can receive user command, or automated by a retrofitting platform [18]. The search for the suitable sensor and matching actuator can adopt the static or dynamic model creation in [67].…”

“…Noticeably, besides existing variables, the retrofitting attempt may introduce new variables which share an impact on the process [54]. In addition, new actuator deployment can extend the capability of the existing hardware, thus incorporating new aspects into the system [80], such as safety [21], [64].…”

“…In general, the availability of data is the foundation for the higher application toward smart manufacturing [74], which is discussed in the next section separately. It is worth mentioning that once the legacy system is retrofitted with the data visualization [127] and equipped with web service [18], or mobile HMI [64], [104]. The operators will be the ones who benefit the most in their work.…”