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

Abstract

The ongoing Industry 4.0 is characterized by the connectivity between components in the manufacturing system. For modern machines, the Internet of Things is a built-in function. In contrast, there are legacy machines in deployment functioning without digital communication. The need to connect them became popular to improve overall production efficiency. As building a new smart factory as a greenfield investment is a capital-intensive choice, retrofitting the existing infrastructure with IoT capability is more reasonable than replacing them. However, this so-called brownfield development, or retrofitting, requires specific prerequisites, e.g., digitization status assessment, technical and connectivity development, management requirement, and operational need, representing a significant disadvantage: lack of scalability. In the meantime, Industry 5.0 is under human-centric priority, which poses new challenges to the retrofitted system. Aware of the challenge, this paper provides a systematic overview of brownfield development regarding technical difficulties, supporting technologies, and possible applications for the legacy system. The research scope focuses on available Industry 4.0 advancements but considers preparing for the forthcoming Industry 5.0. The proposed retrofitting project approach can be a guideline for manufacturers to transform their factories into intelligent spaces with minimal cost and effort but still gain the most applicable solution for management needs. The future direction for other research in brownfield development for Industry 5.0 is also discussed.

Intelligent Retrofitting Paradigm for Conventional Machines towards the Digital Triplet Hierarchy

“…Retrofitting entails integrating obsolete industrial systems with IoT solutions and artificial intelligence prerequisites, assisting them in embarking upon IoT technology, and can be referred to as "IoTization" [36]. The most difficult challenge of a retrofitting project is that an obsolete industrial system and SMEs are the most susceptible to being left behind in the I4.0 development [37], and equipment from different technical eras has distinct communication protocols [38,39]. On the other hand, because of a paucity of advanced sensors and actuators, further strenuous considerations must be determined before initiating a retrofitting project with a particular system.…”

“…The most imperative ones are the contemporary system's digital consciousness, the condition of the machinery, and the performance requirement that determines the type of connectivity. Digital retrofitting [38][39][40][41][42][43][44][45], also known as Brownfield development [37], is an IoT upgrade that improves the utilisation of existing infrastructure with legacy equipment and software. These two definitions, according to some authorities, can be employed alternatively [40].…”

Enhancing Manufacturing Efficiency: A Lean Industry 4.0 Approach to Retrofitting

“…When it comes to manufacturing, considering the new digitalization trends, the need for retrofitting legacy equipment instead of completely new machinery is a preferred option [52], especially for SMEs in less developed countries that have limited resources to invest in bigger digitalization projects. However, although retrofitting seems like a simple solution, there are many factors that could make manufacturers' minds up on whether to retrofit or not [9,11], including:…”

“…J., 41 (2), 123-129 (2023) and technologies that I4.0 offers. Also, many companies, especially small and medium enterprises (SMEs), are not financially capable of implementing these technologies and/or buying entirely new machines that employ these technologies [9]. Considering this challenge, an alternative to taking off to I4.0 with low cost and agility is known as retrofitting, which is the reuse of old equipment and its integration with new I4.0 technologies [15].…”

Demonstration Laboratory of Industry 4.0 Retrofitting and Operator 4.0 Solutions: Education towards Industry 5.0

“…With smart retrofitting, SMEs can transfer the aspects of Industry 4.0 visions to machines or processes effectively with regard to cost and time [ 7 ]. Smart-retrofitting-based development is also an enabler for Industry 5.0 solutions [ 8 ]. Since SMEs have limited resources, smart retrofitting offers a good solution because it is a fast and cost-effective way of reaching Industry 4.0, thereby improving their productivity and competitiveness [ 9 ].…”