SUSTAINABLE

MANUFACTURING
4.0

V MOHAN RAJE
URS
22MEM3R18
 ABSTRA INTRODUCT LITERATURE MOTIVATI
CT ION REVIEW ON

INDUSTRY SUSTAINABLE AGENDA 1

4.0 MANUFACTURING

SM 4.0 30/11/2022 2
2 3 CONCLUSION
 ABSTRACT
• The current globalization is faced by the challenge
to meet the continuously growing worldwide
demand for capital and consumer goods by
simultaneously ensuring a sustainable evolvement
of human existence in its social, environmental and
economic dimensions.
• In order to cope with this challenge, industrial value
creation must be geared towards sustainability.
• Currently, the industrial value creation in the early
industrialized countries is shaped by the
development towards the fourth stage of
industrialization, the so-called Industry 4.0.
• This development provides immense opportunities
for the realization of sustainable manufacturing.

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 INTRODUCTION
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 INTRODUCTION
 Riding on the machines that changed the world, the industry has undergone numerous revolutions:

► from the initial steam engine-powered machines

► to the advent of electricity in industrial processes for mass production,
► then the automated machines which involve advanced electronics and
information technologies in automating the production process
► the fourth industrial revolution—Industry 4.0 (I4.0)—which integrates smart
machines with digital technologies to maximize industrial productivity

 The development towards Industry 4.0 has presently a substantial influence on the
manufacturing industry. It is based on the establishment of smart factories, smart products and
smart services embedded in an internet of things and of services also called industrial internet.
 This development towards an Industry 4.0 provides immense opportunities for realizing
sustainable manufacturing using the ubiquitous information and communication technology
(ICT) infrastructure.

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 LITERATURE
REVIEW
•For7 years since 2015, 248 documents
had been published in 119 various
sources.
•Of the total documents, 39% were
published as journal articles, while 48%
were published as conference papers,
highlighting a great demand for state-of-
the-art studies to further this new line of
research.
•Moreover, 5% and 8% of the total
documents were published as review
papers and others (i.e., conference review,
book chapter, book, editorial),
respectively.
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 LITERATURE GAP AND
MOTIVATION

THE WAY TO GET STARTED IS TO QUIT

TALKING AND BEGIN DOING.
WA LT D I S N E Y

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INDUSTRY
4.0
AN OVERVI EW
 Industry 4.0, has been perceived as a collective term for technologies and concepts of value
chain organization.
Within modular intelligent manufacturing factories 4.0, Cyber-Physical Systems (CPS)
monitor physical processes, create a virtual copy of the physical world, and make
decentralized decisions. Internet of Things (IoT) and CPS communicate and cooperate with
each other and with humans in real time. Through Internet of Services (IoS), both internal
services and interorganizational services are offered and used by participants in the value
chain.
 The Figure shows the general composition of Industry 4.0 or the
fourth industrial revolution. Involving connection and
collaboration, as well as data and analysis as key capabilities, the
industry 4.0 can be distributed in three basic components:
1 - Digitization and integration of vertical and horizontal value chains
2 - Digitization of product and service offerings
3 - Innovative digital business models

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 Digitization and integration of vertical and horizontal value chains.

• The first component refers to the "horizontal integration" that occurs between enterprises
through the value chain and the information network to achieve an integration of resources,
so that enterprises can achieve continuous cooperation and provide real-time products and
services.
• The "vertical integration" is based on the future intelligent factory in the network of
manufacturing system, from the demands to the mode of manufacturing services, to achieve
custom production, instead of the traditional fixed production process (for example, a line of
production).
Digitization of product and service offerings.
• The second component refers to the extension of the existing product range with complete
descriptions of digital products as well as ("embedded systems"/"Internet of Things"). These
include online connection for regular matching of performance and wear data or custom
product development.
Innovative digital business models.
• Finally, the third component consists, in general, of offering Internet services based on a
service-oriented reference architecture.

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 SUSTAINABLE
MANUFACTURING

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 •Sustainable Manufacturing can be defined as the integration of processes and systems capable to produce
high quality products and services using less and more sustainable resources (energy and materials), being
safer for employees, customers and communities surrounding, and being able to mitigate environmental
and social impacts throughout its whole life cycle.
•Benefits of sustainable manufacturing include cost reduction through resource efficiency and regulatory
compliance improvement, better brand reputation, new market access, less labor turnover by creating
attractive workplaces, and long-term business approach by creating opportunities to access financing and
capital.
•The sustainable manufacturing scope in four areas with its respective objects and applied disciplines are
1. Manufacturing technologies (how things are manufactured) with focus on process and equipment (machine-tool,
facility)
2. Product lifecycles (what is to be produced) with focus on product and services’ design; linked discipline is
engineering design;
3. Value creation networks (organizational context) with focus on organizations of companies and manufacturing
networks
4. Global manufacturing impacts (transition mechanisms towards sustainable manufacturing) with focus on studies
about manufacturing impacts on the world, including society, environment, and economy.

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 AGENDA

A POSITIVE OPPORTUNITIES OF
PROSPECT OF SUSTAINABLE
SUSTAINABLE MANUFACTURING
MANUFACTURING IN INDUSTRY 4.0
IN INDUSTRY 4.0.

CAN INDUSTRY 4.0

REALLY PAVE WAY
FOR SUSTAINABLE
MANUFACTURING.

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 A POSITIVE
PROSPECT OF
SUSTAINABLE
MANUFACTURING
IN INDUSTRY 4.0.

Improvements
Main design
in sustainability
principles of
due to these
Industry 4.0
principles

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Industry 4.0
Interoperability
Interoperability is to exchange machines
and equipment that perform the same
function, even from different
manufacturers. This gives rise to multiple
networks in a trusted environment, for
equipment to intercommunicate, enabling
an awareness that is required for the
development of I. 4.0 intelligent
functions
Real-Time Capability
To perform the organizational tasks, it is
necessary that the data is collected and
analyzed in real time but I 4.0. notion of
real-time capability goes a step further. It
includes plants that can react to the
failure of one machine and forward
products to another machine as well as a
throughout linkage between the end
consumer.
SM 4.0
Main design principles of
Decentralization
Decentralization as understood in I 4.0. is
the increased ability of local companies,
operations personal, as well as machines
to make decisions. Instead of using
central computers or pass down decision
hierarchically, capacitating and allowing
local operators to respond to changes and
readapt themselves grants more
flexibility.
Modularity
This principle involves modular systems
that can adapt flexibly to changing
requirements by replacing or expanding
individual modules which makes adding
or removing production modules in a
much easier way.
Virtualization
Virtualization means that through the
usage of monitoring and machine-to-
machine communication a virtual twin
can be abstracted. The sensor data are
linked to virtual plant models and
simulation models. In this way, a virtual
copy of the physical world is created. In
case of failure a human being can be
notified.
Service Orientation
Within this principle, business, human
and CPS services are available through
the internet of services and can be used
by other participants, facilitating the
creation of product-service systems. They
can be offered internally and across
company boundaries.
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 Interoperability
The capacity to use machines from different manufacturers and in different contexts interchangeably can
lead to
• longer machine life cycles and decrease the volume of discarded machines through internal or industry to
industry commerce.
• allows state of the art companies to use the most efficient machines without having to redesign their
production processes.

Decentralization
• With greater opportunity for decentralized decision making, organizational time is decreased and use
available resources better without the need to communicate local realities to foreign decision makers.
• This creates industry that can adapt faster and seize local opportunities, both regarding environmental
resources (such as deciding to buy only from alternative sources or adopting self production of energy)
and market opportunities.
Virtualizatio
n
• Virtualization creates an easier way to follow-up production practices, leading to decrease in industrial
waste because of its advantages to evaluate results and to implement better practices.
• It can also be used, in a partnership with the final user, to increase recycling opportunities since the
virtual self of the product could communicate its status, thus allowing the company to offer a replacement
(and dealing with the old product) or tell the consumer where to discard.

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 Real-Time
Capability
• Better adaptation to demand curves, better use of resources, faster response to energy supply
changes are all results of a faster response to changes. If costumer behavior changes, this can
help avoid overproduction.
Modularity

• Being able to add and remove processes in a modular way allows for a more flexible and thus
longer use of machines due to the increased ability of reuse. This goes together with the
advantages of Interoperability
Service
Orientation
• Improved usage of final products, increased recycling and reuse opportunities are already seen
as a result of Product-Service-Systems and I 4.0. orientation towards service goes in the same
direction.
• By increase the usage percentage of highly environmentally demanding assets, such as car and
manufacturing equipment, a decrease in waste, resources and energy consumption is immediate.

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 OPPORTUNITIES OF
SUSTAINABLE
MANUFACTURING IN
INDUSTRY 4.0

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 Macro perspective of Industry
4.0
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 Business Models

• In Industry 4.0, new evolving business models are highly driven using smart data for
offering new services. This development must be exploited for anchoring new
sustainable business models.
• Sustainable business models significantly create positive or reduce negative impacts for
the environment or society or they can even fundamentally contribute to solving an
environmental or social problem.
• Additionally, sustainable business models are necessarily characterized by
competitiveness on the long-run.
Value Creation Networks

• The cross-linking of value creation networks in Industry 4.0 offers new opportunities
for realizing closed-loop product life cycles and industrial symbiosis.
• It allows the efficient coordination of the product, material, energy, and water flows
throughout the product life cycles as well as between different factories.
• Closed-loop product life-cycles help keep products in life cycles of multiple use phases
with remanufacturing or reuse in between.

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 Micro perspective
of Industry 4.0

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 Equipment
• The manufacturing equipment in factories often is a capital good with a long use phase of up to 20 or more years.
• Retrofitting enables an easy and cost-efficient way of upgrading existing manufacturing equipment with sensor and
actuator systems as well as with the related control logics in order to overcome the heterogeneity of equipment in
factories.
Human
Resource
• Three different sustainable approaches can be used for coping with the social challenge in Industry 4.0.
(1) Increasing the training efficiency of workers by combining new ICT technologies (information and communication
technology)
(2) Increasing the intrinsic motivation and fostering creativity by establishing new CPS-based approaches of work
organization and design.
(3) Increasing the extrinsic motivation by implementing individual incentive systems for the worker.
Organization
• A sustainable-oriented decentralized organization in a smart factory focuses on the efficient allocation of products,
materials, energy and water by considering the dynamic constraints of the CPS.

Process
• The sustainable design of processes addresses the holistic resource efficiency approach of Industry 4.0 by designing
appropriate manufacturing process chains

Product
• The approach for the sustainable design of products in Industry 4.0 focuses on the realization of closed-loop life cycles
for products by enabling the reuse and remanufacturing of the specific product or by applying cradle-to-cradle
principles.
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 CAN INDUSTRY 4.0
PAVE WAY FOR
SUSTAINABLE
MANUFACTURING.

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 General framework of I 4.0 and
SM 4.0
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Big Data Analytics
Capable of Improving
direct/indirect costs, waste and
emissions, and product end-of-
life management at the product
level.
energy consumption and
environmental impact at the
process level.
net profit, operational
performance, material use and
efficiency, energy use and
efficiency, and water use and
efficiency at the system level.
SM 4.0
CAPABILITIES OF I4.0 ELEMENTS TO
TRANSFORM SM
Virtual and Augmented
Reality
Capable of improving
quality and durability,
functional performance, and
safety and health impact at the
product level.
manufacturing cost, personnel
health, and operational safety at
the process level.
net profit, operational
performance, health and safety,
and stakeholder engagement at
the system level.
Optimization and
Simulation
Capable of Improving
performance at the product
level.
manufacturing cost, energy
consumption, environmental
impact, personnel health, and
operational safety at the process
level.
capital charge, manufacturing
cost, operational performance,
material use and efficiency,
energy use and efficiency,
water use and efficiency, waste
and emission, and stakeholder
engagement at the system level.
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Additive Manufacturing
Capable of Improving
 initial investments, material
use and efficiency, energy use
and efficiency at the product
level.
 personnel health and
operational safety at the
process level.
 net profit, operational
performance, health and
safety, and stakeholder
engagement at the system
level
SM 4.0
Cloud
Capable of improving
 functional performance,
product end-of-life
management, and safety and
health impact at the product
level.
 manufacturing cost and
waste management at the
process level.
 net profit, manufacturing
cost, operational
performance, health and
safety, and stakeholder
engagement at the system
level.
Industrial Internet of
Things
Capable of Improving
 benefits and losses, product
quality and durability, and
product end-of-life
management at the product
level
 manufacturing cost, waste
management, personnel
health, operational safety at
the process level
 net profit, capital charge,
operational performance,
health and safety, and
stakeholder engagement at
the system level.
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 CONCLUSION
• In order to give a comprehensive understanding of the
developments in Industry 4.0 leaning towards Sustainable DEVEL
manufacturing, positive aspects of I4.0 have been described OP
based on the current findings in research and practice.
• Subsequently, different opportunities for realizing a UNDERSTA
sustainable manufacturing in Industry 4.0 have been ND
presented for the macro as well as for the micro perspectives.
• These opportunities are combining current research
approaches in the field of sustainable manufacturing with the
future requirements of Industry 4.0.
• Lastly the possibility of the new revolution due to clash of
I4.0 and SM have been realized.

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 REFERENCES
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positive prospect in Sustainable Manufacturing. Procedia Manuf. 2018, 21, 671–678.
• Byrne, G.; Dimitrov, D.; Monostori, L.; Teti, R.; van Houten, F.; Wertheim, R. Biologicalisation: Biological
transformation in manufacturing. CIRP J. Manuf. Sci. Technol. 2018, 21, 1–32.
• Franciosi, C.; Iung, B.; Miranda, S.; Riemma, S. Maintenance for Sustainability in the Industry 4.0 context: A
Scoping Literature Review. IFAC-PapersOnLine 2018, 51, 903–908.
• Kagermann, H.; Lukas, W.; Wahlster, W.: Industrie 4.0 - Mit dem Internet der Dinge auf dem Weg zur 4.
industriellen Revolution. In: VDI Nachrichten, Issue 13
• Gausemeier, J.; Czaja, A.; Dülme, C.: Innovationspotentiale auf dem Weg zu Industrie 4.0. In: Wissenschafts-
und Industrieforum Intelligente Technische Systeme 2015, Heinz Nixdorf Institut
• T. Stock*, G. Seliger, Opportunities of Sustainable Manufacturing in Industry 4.0
• Hamed Gholami ,* , Falah Abu , Jocelyn Ke Yin Lee , Sasan Sattarpanah Karganroudi 3 and Safian Sharif 1,
Sustainable Manufacturing 4.0—Pathways and Practices

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 THANK YOU
• V MOHAN RAJE URS
• 22MEM3R18
• VM22MEM3R18@STUDENT.NITW.
AC.IN

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