Industry 4.0 Concepts and Lean Methods Mitigating Traditional Losses in Engineer-to-Order Manufacturing with Subsequent Assembly On-Site: A Framework

Abstract Engineer-to-Order companies design and manufacture complex products based on specific customer requirements. Their project-driven processes and non-repetitive production causes various inefficiencies, which lead to productivity losses. Conventional approaches such as Lean Manufacturing and Lean Construction are limited in mitigating these losses due to their challenging implementation in the Engineer-to-Order environment. New concepts and technologies from Industry 4.0 have the potential to mitigate these losses through digitizing processes but are little researched in the Engineer-to-Order industry. This article classifies traditional losses from Engineer-to-Order manufacturing companies and through literature review identifies several Lean as well as Industry 4.0 methods that have the potential to mitigate these losses. The results are presented in a framework which can be used to develop a Lean and Industry 4.0 assessment tool for companies supporting the implementation of these concepts to mitigate the presented loss categories. Further research should focus on validating the framework with empirical data

Anthropocentric perspective of production before and within Industry 4.0

Abstract This paper presents a systematic literature review (SLR) of the anthropocentric perspective of production before and after (or, better, within) Industry 4.0. We identify central research clusters regarding traditional Anthropocentric Production Systems (APS) and Anthropocentric Cyber Physical Production Systems. By comparing the two perspectives, we are able to analyse new emerging paradigms in anthropocentric production caused by Industry 4.0. We further make prediction of the future role of the human operator, his needed knowledge and capabilities and how assistance systems support the Operator 4.0. Our paper gives a brief outlook of current and needed future research. It builds grounds for further scholarly discussion on the role of humans in the factory of the future

Axiomatic Design Based Guidelines for the Design of a Lean Product Development Process

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The way from Lean Product Development (LPD) to Smart Product Development (SPD)

Abstract Lean Product Development (LPD) is the application of lean principles to product development, aiming to develop new or improved products that are successful in the market. LPD deals with the complete process from gathering and generating ideas, through assessing potential success, to developing concepts, evaluating them to create a best concept, detailing the product, testing/developing it and handing over to manufacture. With the beginning of the fourth Industrial Revolution (Industrial 4.0) and the rising efforts to realize a smart factory environment, also product development has to perform a substantial transformation. This paper firstly describes the concept of Lean Product Development as well as new requirements for an intelligent and Smart Product Development (SPD) through the introduction of modern Industry 4.0 related technologies. Based on Axiomatic Design methodology, a set of guidelines for the design of Lean Product Development Processes is presented. These guidelines are linked with concepts from Industry 4.0 in Engineering, showing how a lean and smart product development process can be achieved by the use of advanced and modern technologies and instruments

Critical Factors for Introducing Lean Product Development to Small and Medium sized Enterprises in Italy

Abstract Small and medium sized enterprises are the backbone of many economies. Especially in Italy SME's play a major role in the economic system. In the last years many lean methods and approaches were introduced successfully also in small and medium sized enterprises. After a successful introduction in manufacturing the lean approach swapped also on other indirect areas such as engineering and product development. Actually in research we can find only few research on the application of Lean in the R&D departments of SME's. The novelty of this paper is to provide a survey based evaluation of applicability, benefits as well as critical factors of Lean in SME product development. In the survey 54 Italian SME's were asked for their opinion. Further, respondents gave a statement on the introduction of emerging Industry 4.0 techniques in product development and how they can influence the effect of Lean in product development. The main results are that numerous Lean methods can be introduced very quickly promising high potential for improvements and that Lean methods combined with Industry 4.0 technologies act like a booster for efficiency optimization in product development

Urban production – A socially sustainable factory concept to overcome shortcomings of qualified workers in smart SMEs

Abstract Many of the Industry 4.0 approaches are of a technical nature, and by developing new intelligent technologies and adapting and transferring existing techniques, they will help increase productivity in industry. However, human resources will play a central role also in future factories, thus they are a key factor for implementing Industry 4.0. The role and job profile of employees in the smart factories will change in the future and it will be increasingly challenging for SMEs to compete with large corporations in the fight for skilled workers. In the smart city of tomorrow, production sites will be integrated in the sense of an 'urban production' in a city-friendly way becoming more interesting for talents and qualified work force. Thus, this paper discusses the imminent shortage of skilled workers with a focus on SMEs. The proposed concept of urban production gives an overview of measures to overcome the shortage of qualified workers. The paper aims to show that urban production is a concept to achieve a socially sustainable symbiosis between companies and the city of the future

BIM, Augmented and Virtual Reality empowering Lean Construction Management: a project simulation game

Abstract During the last decades, Lean Management methodologies established in the manufacturing environment have been applied and adapted to the construction industry under the term "Lean Construction". Currently, concepts and technologies from Industry 4.0 are mainly transforming the manufacturing industry and only few applications have been implemented to construction and its connected supply chains. This paper shows how new technologies like Building Information Modeling connected with Virtual and Augmented Reality could empower Lean Construction methodologies to increase efficiency during the building execution process. The approach was tested by using the project simulation game Villego® with students from the course "Project Management" of the master degree LM-33 "Industrial Mechanical Engineering" of the Free University of Bozen-Bolzano

Simulation Based Validation of Supply Chain Effects through ICT enabled Real-time-capability in ETO Production Planning

Abstract According to Industry 4.0, real-time information in production planning and control, shows a high potential for optimizing the whole supply chain. The paper considers the plant building industry, especially the off-site fabrication and on-site installation. Traditionally, production planning is centralized following a Master Schedule that rarely is up to date, ignoring deviations on-site. As a result, components are delivered in advance or too late, which create non-value adding activities and high inventory levels. The paper proposes an ICT-supported nearly real-time capable production planning approach, which by means of a simulation, shows a drastically reduction of the inventory level on-site

One-to-one relationships between Industry 4.0 technologies and Lean Production techniques: a multiple case study

Production research literature and industry practice have started to pay increasing attention to the Industry 4.0 (I4.0) phenomenon. Scholars and practitioners identified a strong link between this paradigm and the well-known Lean Production (LP) paradigm. Most studies consider LP as a prerequisite of I4.0 and I4.0 as a tool to overcome LP limits and boost its practices. However, so far, these effects have been studied only at a high level, without an in-depth and comprehensive pairwise analysis at a practice-technology level. Moreover, few empirical studies have been carried out on this topic. Our paper attempts to fill these gaps by conducting a multiple case studies research to explain the one-to-one relationships between LP techniques and I4.0 technologies, and vice versa. More specifically, the one-to-one analysis examines the enabling effect of LP on I4.0 and the empowering effect of I4.0 on LP. Based on the empirical analyses, we propose a framework on the relationships between the two paradigms structured into six areas drawn from previous research (i.e., manufacturing equipment and processes, shop-floor management, workforce management, new product development, supplier relationships, customer relationships). Such representation clarifies the interdependence of the two paradigms in the whole supply chain

Digitalized manufacturing logistics in engineer-to-order operations

This is a post-peer-review, pre-copyedit version of an article published in Advances in Production Management Systems. Production Management for the Factory of the Future. APMS 2019. IFIP Advances in Information and Communication Technology, vol. 566. The final authenticated version is available online at: https://doi.org/10.1007/978-3-030-30000-5_71. The high complexity in Engineer-To-Order (ETO) operations causes major challenges for manufacturing logistics, especially in complex ETO, i.e. one-of-a-kind production. Increased digitalization of manufacturing logistics processes and activities can facilitate more efficient coordination of the material and information flows for manufacturing operations in general. However, it is not clear how to do this in the ETO environment, where products are highly customized and production is non-repetitive. This paper aims to investigate the challenges related to manufacturing logistics in ETO and how digital technologies can be applied to address them. Through a case study of a Norwegian shipyard, four main challenges related to manufacturing logistics are identified. Further, by reviewing recent literature on ETO and digitalization, the paper identifies specific applications of digital technologies in ETO manufacturing. Finally, by linking manufacturing logistics challenges to digitalization, the paper suggests four main features of digitalized manufacturing logistics in ETO: (i) seamless, digitalized information flow, (ii) identification and interconnectivity, (iii) digitalized operator support, and (iv) automated and autonomous material flow. Thus, the paper provides valuable insights into how ETO companies can move towards digitalized manufacturing logistics