Smart Retrofitting by Design Thinking Applied to an Industry 4.0 Migration Process in a Steel Mill Plant

Burresi, Giovanni; Ermini, Sara; Bernabini, Dario; Lorusso, Martino; Gelli, Federico; Frustace, Davide; Rizzo, Antonio

doi:10.1109/meco49872.2020.9134210

Cited by 13 publications

(29 citation statements)

References 3 publications

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“…Industrial robot [17], Assembly line [77], Metal forming [97], [112], Modular Production System [56], Candy packaging [52], Lab experiment [113], [119] Python-OPC UA High-bay shelf warehouse [94] OPC DA Steel Mill [20]…”

Section: Communication Protocolmentioning

confidence: 99%

“…Plastic injection [114], Electronic manufacturing [76], Industrial motor-driven system [85], Oil extraction [54], Steel Mill [20], Food processing [51], Oilfield [81], CNC machining [88], [127], [128], Textile [15], Metal casting [125], Aluminium casting [80], Didactic plant [18], Metal cutting [93], Glass forming [39], Water industry [112], Metal forming [58], Metal de-burring and grinding [103] Process automation…”

Section: Process Parameters Trackingmentioning

confidence: 99%

“…Plastic injection [114], Electronic manufacturing [76], Iron & Steel production [84], Limestone processing [90], Industrial equipment [86], Steel Mill [20], Car assembly [75], Oilfield [81], CNC machining [115], [127], [128], Metal cutting [93], Industrial robot [82], Material handling [104], Assembly line [77],…”

Section: Process Parameters Trackingmentioning

confidence: 99%

“…The objects in retrofitting include the hardware of machinery and the production method, operator, and management as stated in Ref. [20]. The most challenging obstacle of a retrofitting project is that in a legacy system, there are machine tools from different manufactured times, thus having different communication protocols [21].…”

Section: Introductionmentioning

confidence: 99%

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

Tran

Ruppert

Eigner³

et al. 2022

IEEE Access

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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.

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Section: Communication Protocolmentioning

confidence: 99%

Section: Process Parameters Trackingmentioning

confidence: 99%

Section: Process Parameters Trackingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

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

Tran

Ruppert

Eigner³

et al. 2022

IEEE Access

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“…An important aspect related to Industry 4.0 and retrofitting for its implementation is undoubtedly the safety of operators. Burresi et al [27], in the retrofitting of a steel mill plant through the implementation of a CPS, in addition to efficiency objectives, also have the aim of improving the safety of operators, obtaining benefits not only in terms of increasing productivity but also in training new operators.…”

Section: Literature Reviewmentioning

confidence: 99%

Retrofitting a Process Plant in an Industry 4.0 Perspective for Improving Safety and Maintenance Performance

2021

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The transformation from traditional industry to Industry 4.0 can bring many benefits in various spheres, from efficiency to safety. However, this transition involves adopting technologically advanced machinery with a high level of digitization and communication. The costs and time to replace obsolete machines could be unsustainable for many companies while retrofitting the old machinery. To make them ready to the Industry 4.0 context, they may represent an alternative to the replacement. Even if there are many studies related to retrofitting applied to machinery, there are very few studies related to the literature process industry sector. In this work, we propose a case study of a two-phase mixing plant that needed to be enhanced in the safety and maintainability conditions with reasonable times and costs. In this regard, the Digital Twin techniques and Deep Learning algorithms will be tested to predict and detect future faults, not only already visible and existing malfunctions. This approach strength is that, with limited investments and reasonable times, it allows the transformation of an old plant into a smart plant capable of communicating quickly with operators to increase its safety and maintainability.

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Retrofitting Industrial Machines with WebAssembly on the Edge

Nakakaze

Koren

Brillowski

et al. 2022

Web Information Systems Engineering – WISE 2022

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Smart Retrofitting by Design Thinking Applied to an Industry 4.0 Migration Process in a Steel Mill Plant

Cited by 13 publications

References 3 publications

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

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

Retrofitting a Process Plant in an Industry 4.0 Perspective for Improving Safety and Maintenance Performance

Retrofitting Industrial Machines with WebAssembly on the Edge

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