Study of Industry 4.0 and its Impact on Lean Transformation in Aerospace Manufacturing

2019 ◽  
Author(s):  
Sagil James ◽  
Alejandro Cervantes
Keyword(s):  
Lean Manufacturing ◽  
Industry 4.0 ◽  
Manufacturing Sector ◽  
Discrete Event ◽  
Hybrid Approach ◽  
Manufacturing Industries ◽  
Lean Principles ◽  
Aerospace Manufacturing ◽  
Lean Transformation

Abstract Lean manufacturing practices focus on minimizing all forms of waste from the production system. The applicability of lean manufacturing concepts and principles has often been questioned in sectors including aerospace manufacturing primarily due to their high variety - low volume environments. The key challenges include the difficulty in changing the factory layout, lack of plant-specific manufacturing strategies, lack of benchmarking between manufacturing plants and non-existence of learning through experimentation culture. Consequently, the aerospace manufacturing industries have struggled to implement lean principles over the years successfully. Industry 4.0 is a new paradigm that is significantly influencing several manufacturing industries across the globe. Applying the concepts of Industry 4.0 along with the conventional lean transformation technology could potentially address these challenges. The focus of this research is to study the possibilities of integrating Industry 4.0 tools with existing lean manufacturing philosophies within the aerospace manufacturing sector in order to improve various aspects of manufacturing processes in a cyber-physical environment. A case study is performed considering a quality inspection department in a typical aerospace industry. The case study is simulated using discrete event simulation tool — Arena. The study found that a hybrid approach involving the holistic merger of the lean principles along with the Industry 4.0 tools known as Lean Industry 4.0 is the best way forward for the aerospace manufacturing sector. The outcomes of this research provide an understanding of the role of industry 4.0 paradigm and their implementation in several other high-technology and high-risk manufacturing sectors including life sciences, space, and defense industries.

scholarly journals Industrial Case Study on Lean Manufacturing Implemented on Manufacturing Polypropylene Ropes Industry Amravati

2021 ◽  
Vol 9 (12) ◽  
pp. 1318-1323
Author(s):  
Vipul Deshpande
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Service Industry ◽  
Developing Economies ◽  
Labour Productivity ◽  
Shop Floor ◽  
Industrial Case Study ◽  
Lean Principles ◽  
Manufacturing Techniques

Abstract: Lean manufacturing has been one of the most standard method in the manufacturing and service industry for elimination of waste. Every manufacturing industry has to put in continuous effort for its survival in the current impulsive and competitive economy. The purpose of this paper is to investigate the adoption of lean manufacturing tools and techniques in the manufacturing industries. This paper is based on actual implementation of lean manufacturing techniques. It focuses on the execution of flow from the start until the end of the implementation, types of analysis and tools applied, evaluation methods and how the industry benefited from the implementation. In this case study we particularly focused on Shop floor management, Quality Management (QM), Supplier and Customer Management (SCM) and Workforce Management (WM). After going through various testing on implementation of Lean Manufacturing principles in Micro Small medium Enterprise (MSME), researcher studied thoughts of some author where they discussed pragmatic problems they overcome while implementing lean principles in developing economies MSME. At the end, the result shows that there is monthly increment in capital productivity and labour productivity. And decrement in inhouse rejection, breakdown hours and customer complaint from the implementation of lean.

scholarly journals An empirical research on achieving success with Lean

2021 ◽  
pp. 212-222
Keyword(s):  
Empirical Research ◽  
Lean Manufacturing ◽  
Study Results ◽  
Key Concepts ◽  
Lean Transformation ◽  
Operational Practices

Several companies apply lean manufacturing however the implementation in organizations is not always successful. One of the difficulties is deciding which of the lean approach to avoid the failure; therefore this paper reviews the key concepts and attributes of the lean paradigm, and identifies how they can be applied to ETP’s current operational practices. The study results show a successful lean transformation case study. Practically, this is a comprehensive guideline for practitioners to implement Lean in their organizations to make better decisions.

scholarly journals Implementation of industry 4.0 to achieve sustainable manufacturing in steel industry: a case study

2021 ◽  
Vol 2 (1) ◽  
pp. 1-9
Author(s):  
Pradeep Kumar
Keyword(s):  
Steel Industry ◽  
Industry 4.0 ◽  
Manufacturing Industry ◽  
Industrial Revolution ◽  
Manufacturing Sector ◽  
Sustainable Manufacturing ◽  
Agile Manufacturing ◽  
The One ◽  
The Internet Of Things

Sustainable manufacturing has been a popular topic of research for quite some time now. There are various concepts and ideas which have claimed to have a significant impact on sustainability of the manufacturing industry like lean, green and agile manufacturing. Industry 4.0 is the latest and by far the one with the maximum potential of changing the manufacturing sector forever. It is rightly called as “the fourth industrial revolution”. It is a wide concept which covers many state of the art technologies like the Internet of Things (IoT), Artificial Intelligence, Big Data, Augmented reality etc. But like every big revolution, it is to face many challenges also. In this review, we are looking at this ‘yet in infancy’ concept and its role in achieving a sustainable manufacturing sector as discussed by researchers. Different scholars have come up with different challenges to implementation of I4.0 which they thought to be of some significance. There is going to  review such challenges making a list of 13 such challenges. Then, it also throw some light on the new challenge faced by all of humanity in the form of SARS-CoV-2 pandemic and how it is affecting the manufacturing sector.

scholarly journals An Agile System to Enhance Productivity through a Modified Value Stream Mapping Approach in Industry 4.0: A Novel Approach

2021 ◽  
Vol 13 (21) ◽  
pp. 11997
Author(s):  
Varun Tripathi ◽  
Somnath Chattopadhyaya ◽  
Alok Bhadauria ◽  
Shubham Sharma ◽  
Changhe Li ◽  
...  
Keyword(s):  
Industry 4.0 ◽  
Manufacturing Sector ◽  
Value Added ◽  
Value Stream Mapping ◽  
Just In Time ◽  
Value Stream ◽  
Novel Approach ◽  
Decision Making Processes ◽  
Machinery Manufacturing

Worldwide, industries are emphasizing the development of an agile system to sustain higher productivity, which can be applied to ensure improvements in all production conditions in industry 4.0. In the present scenario, several methods are used for improvements in production, such as value stream mapping, kaizen, just in time, Kanban, and total productive maintenance, etc., The objective of the present research article is to produce an agile system to sustain improvements in productivity through a methodology coupled with value stream mapping in industry 4.0. Value stream mapping is a lean-based method and is used for the maximization of productivity by the elimination of non-value-added activities. The proposed methodology has been validated by productivity enhancements achieved in a case study of the earthmoving machinery manufacturing sector. The study establishes that the proposed methodology would encourage industry personnel during decision-making processes, which would lead to improvements in production in industry 4.0.

scholarly journals Changing Scenario of Manufacturing Industries Due to Covid 19

2021 ◽  
Vol 7 (01) ◽  
pp. 81-84
Author(s):  
Ruchira Srivastava and Vijay Kumar Srivastava
Keyword(s):  
Industry 4.0 ◽  
Manufacturing Sector ◽  
Manufacturing Industries

The introduction of Industry 4.0 were already generating various changes in operations of manufacturing sector before the pandemic situation and now after the pandemic conditions things have become more tough and challenging. Since March 23rd 2019 the home quarantine and lockdown situation has completely shut down the whole country after this pandemic condition started trending across the globe. The main objective of this paper is to study about these challenges which are being faced by the manufacturing industries. & how these situations are tackled in Covid 19.

scholarly journals Pivoting Lean Manufacturing through Industry 4.0 in the Indian Context

2019 ◽  
Vol 8 (2) ◽  
pp. 1-7
Author(s):  
Protik Basu ◽  
Pranab K. Dan
Keyword(s):  
Lean Manufacturing ◽  
Industry 4.0 ◽  
Industrial Revolution ◽  
Manufacturing Sector ◽  
Empirical Studies ◽  
Research Work ◽  
Production Model ◽  
Lean Management ◽  
Technological Developments ◽  
Indian Manufacturing Sector

Industry 4.0 and lean management both focus on increasing productivity of industrial systems. Industry 4.0 is foreseen to revolutionize today’s manufacturing environment whereas lean management is an integrated techno-operational system which has gained increasing importance in recent times to bring about a competitive state in an organization. Though in the last three decades there have been rigorous studies on lean manufacturing (LM), its implementation in the Indian manufacturing domain is still in its nascent stage. A lack of research to explore the potential use of Industry 4.0 is also noted. Research work on the compatibility of Industry 4.0 with LM is scarce and any study on the role of Industry 4.0 on LM in the Indian manufacturing sector is practically unavailable. The aim of this research is to explore how the fourth industrial revolution, referred to as Industry 4.0, can strategize LM in the Indian manufacturing context. Empirical studies have disclosed that Indian managers are hesitant to go for automation and technological developments. Results of this work reveal that there needs to be a change in attitude and approach. Lean implementers in India need to embrace Industry 4.0 to pivot LM by automating through Cyber-Physical Systems and creating a flexible design and production model of customized and smart products.

scholarly journals Context-aware architecture for Industry 4.0-ready manufacturing facility

2021 ◽  
Vol 8 (8) ◽  
pp. 20-30
Author(s):  
Olayan Alharbi ◽  
◽  
Mafawez Alharbi ◽  
Keyword(s):  
Mathematical Model ◽  
Industry 4.0 ◽  
Historical Data ◽  
Manufacturing Sector ◽  
Context Aware ◽  
Planning Systems ◽  
Manufacturing Facility ◽  
Extensive Data ◽  
Context Aware System

The industry 4.0 revolution is empowering the manufacturing sector with several advantages from the production to consumption stage of products, or beyond that. Recently, operators in factories have been accumulating extensive data from machine sensors and other organizational and operational technologies such as company enterprise and planning systems. Notably, having access to extensive data is a double-edged sword. To the best of our knowledge, there is not any work in the literature that proposed architecture for industry 4.0 based on a context-aware system. The aim of this research is to provide the context-aware architecture to enhance decision-making in factories and reduce the exposure of operators to the necessary and related findings. The proposed system is contextually aware of three aspects, operator feedback for previous similar findings, specifications of products under production, and historical data of manufacturing machines. The proposed system is proactive which attracted operator attention only when the findings were contextually related, based on the aforementioned aspects. The contributions of this research an intelligent architecture, a case study, and a mathematical model.

scholarly journals Managerial and Industry 4.0 solutions for fashion supply chains

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Marcello Braglia ◽  
Leonardo Marrazzini ◽  
Luca Padellini ◽  
Rinaldo Rinaldi
Keyword(s):  
Supply Chains ◽  
Lean Manufacturing ◽  
Industry 4.0 ◽  
Design Methodology ◽  
Industrial Case Study ◽  
Content Type ◽  
Enabling Technologies ◽  
Production Orders ◽  
Practical Implications

PurposeThe purpose of this paper is to present a structured framework whose objectives are to identify, analyse and eliminate fashion-luxury supply chains inefficiencies.Design/methodology/approachA Lean Manufacturing tool, the 5-Whys Analysis, has been used to find out the root causes associated with the problem identified from a data analysis of production orders of a fashion-luxury company. A case study, which explains the methodology and illustrates the capability of the tool, is provided.FindingsThis tool can be considered a suitable instrument to identify the causal factors of inefficiencies within luxury supply chains, suggesting potential countermeasures able to eliminate the problems previously highlighted. In addition, enabling technologies that deal with Industry 4.0 are associated with the root causes to enable further improvement of the supply chain.Practical implicationsThe effectiveness and practicality of the tool are illustrated using an industrial case study concerning an international Italian signature in the world of fashion-luxury footwear sector.Originality/valueThis framework provides practitioners with an operative tool useful to highlight where the major inefficiencies of fashion-luxury supply chains take place and, at the same time, individuates both the root causes of inefficiencies and the corresponding corrective actions, even considering Industry 4.0 enabling technologies.

Collaborative approach to digital transformation (CADT) model for manufacturing SMEs

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jonathan Brodeur ◽  
Robert Pellerin ◽  
Isabelle Deschamps
Keyword(s):  
Industry 4.0 ◽  
Manufacturing Industry ◽  
Digital Transformation ◽  
Collaborative Approach ◽  
Longitudinal Case Study ◽  
Content Type ◽  
Aerospace Manufacturing ◽  
Research Findings ◽  
New Perspective

PurposeThis paper aims to propose a collaborative approach model developed based on observations of two aerospace manufacturing small and medium-sized enterprises (SMEs) pursuing their digital transformation toward Industry 4.0.Design/methodology/approachThis research focuses on two manufacturing SMEs in North America, and data were collected using longitudinal case study and research intervention method. Data collection was performed through observation and intervention within the collaborative projects over 18 months.FindingsA model of a collaborative approach to digital transformation (CADT) for manufacturing SMEs was produced. Based on the study findings, the collaboration manifests itself at various stages of the transformation projects, such as the business needs alignment, project portfolio creation, technology solution selection and post-mortem phase.Research limitations/implicationsResearch using the case study method has a limitation in the generalization of the model. The CADT model generated in this study might be specific to the aerospace manufacturing industry and collaboration patterns between manufacturing SMEs. The results could vary in different contexts.Practical implicationsThe proposed CADT model is particularly relevant for manufacturing SMEs' managers and consultants working on digital transformation projects. By adopting this approach, they could better plan and guide their collaboration approach during their Industry 4.0 transformation.Originality/valueThis research provides a new perspective to digital transformation approaches in the aerospace industry. It can be integrated into other research findings to formulate a more integrated and comprehensive CADT model in industries where SMEs are significant players.

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