A comprehensive review of Lean manufacturing using constraints theory with Context to Industry 4.0

Khawaish Gupta; Sanjeev Gupta

A comprehensive review of Lean manufacturing using constraints theory with Context to Industry 4.0

Authors

Khawaish Gupta Shri Mata Vaishno Devi University
Sanjeev Gupta Government College of Engineering and Technology Jammu

Keywords:

Constraints, industry 4.0, IR4, industrial revolution, lean manufacturing, theory of constraints

Abstract

There has been continuous research in finding out novel and cost-effective methods of manufacturing in order to cater multifold surge in demand for products in market. Competition in the manufacturing industry is growing and concerned companies have been pressured to take measures and change their manufacturing processes in order to stay competitive on a global market. Constraints are factors that limit the operational capacity of a manufacturing facility and it is the job of managers to remove these barriers in order to increase outcome and profit. Lean manufacturing, an approach geared towards achieving operational excellence, focuses on waste elimination, process optimization, and ongoing productivity improvement. This methodology aligns seamlessly with the goals of Industry 4.0, which promotes smart manufacturing, efficiency, and flexibility. The combination of lean manufacturing and Industry 4.0 within the theory of constraints provides a synergistic solution to address the complexities and challenges posed by advanced technologies and interconnected systems By leveraging advanced technologies, engaging employees, and adopting a data-driven mindset, manufacturers can successfully navigate the complexities of modern manufacturing and gain a competitive edge in the dynamic marketplace It will also examine the challenges associated with implementing these methodologies in various production systems. Through this research paper, the aim is to invoke novel possibilities in merging lean manufacturing processes with Industry 4.0.

References

C. Cheng, T. Guelfirat, C. Messinger, J. Schmitt, M. Schnelte and P. Weber, "Semantic degrees for industrie 4.0 engineering: deciding on the degree of semantic formalization to select appropriate technologies," in Proc. 10th Joint Meeting on Foundations of Software Engineering (ESEC/FSE 15), Italy, 2015, pp. 1010–1013.

M. Hermann, T. Pentek and B. Otto, "Design principles for industrie 4.0 scenarios: a literature review," in Proc. 49th Hawaii International Conference on System Sciences (HICSS), USA, 2016, pp. 3928–3937.

Bitkom, Vdma and ZVI;, "Implementation strategy industrie 4.0,”Frankfurt, Report on the results of the industrie 4.0 platform, 2016.

J. Posada et al., "Visual computing as a key enabling technology for industrie 4.0 and industrial internet," IEEE Computer Graphics and Applications, vol. 35, no. 2, pp. 26–40, Mar.-Apr. 2015.

J. Smit, S. Kreutzer, C. Moeller and M. Carlberg, “Industry 4.0,” Policy department A: economic and scientific policy, Rep. European Parliament's Committee on Industry, Research and Energy (ITRE), 2016.

M. Falk, M. Klien and G. Schwarz, “Large manufacturing firms plan to increase their investments in 2015. Results of the wifo spring 2015 investment survey,” WIFO Monatsberichte (monthly reports), vol.88, no.7, pp. 581–591, 2015.

G. Tassey, “Competing in advanced manufacturing: the need for improved growth models and policies,”Journal of Economic Perspectives, vol.28, no.1, pp. 27–48, 2014.

H. Lasi, P. Fettke, H.G. Kemper, T. Feld and M. Hoffmann, “Industry 4.0,” Business & Information Systems Engineering, vol.6, no.4, pp. 239–242, 2014.

H. Kagermann, W. Wahlster and J. Helbig, “Recommendations for implementing the strategic initiative industrie 4.0,” Acatech -Nacional Academy of Science and Engineering, Frankfurt, Final Rep. of the industrie 4.0 working group. Abr. 2013.

European Commission. Horizon 2020: the EU framework programme for research and innovation. (accessed 2017, May). Available: https://ec.europa.eu/programmes/horizon2020/

The Industrial Internet Consortium: A global nonprofit partnership of industry, government and academia, 2014. Available: http://www.iiconsortium.org/about-us.htm.

K.Q.Li, “Report on the work of the government,” in Proc. Thirdsession of the 12th nacional people’s congress, China, March, 2015.

E. Alkaya, M. Bogurcu, F. Ulutas and G.N. Demirer, “Adaptation to climate change in industry: emproving resource efficiency through sustainable production applications,” Water Environment Research,vol.87, no.1, pp.14–25, Jan. 2015.

R. Schmidt, M. Möhring, R. Härting, C. Reichstein, P. Neumaier and P. Jozinović, “Industry 4.0-potentials for creating smart products: empirical research results,” International Conference on Business Information Systems (BIS), vol. 208, Jun. 2015, pp. 16–27.

T. Bauernhansl, M. Ten Hompel and B. Vogel-Heuse, Industrie 4.0 in Produktion, Automatisierung und Logistik. German: Springer Vieweg, 2014.

A. Khan and K. Turowski, “A survey of current challenges in manufacturing industry and preparation for Industry 4.0,” in Proc. First International Scientific Conference “Intelligent InformationTechnologies for Industry” (IITI’16), Russia, 2016, pp.15–26.

M. Bahrin, F. Othman, N. Azli and M. Talib, “Industry 4.0: a review on industrial automation and robotic,” Jurnal Teknologi, vol. 78, no.6-13, pp.137–143, 2016.

European Commission. High performance production through 3D-printing. (accessed 2017, Apr.). Available:http://s3platform.jrc.ec.europa.eu/high-performance-production-through-3d-printing

M. Cotteleer, J. Holdowsky, and M. Mahto, “The 3D opportunity primer: the basics of additive manufacturing,” Deloitte University Press, 2013.

European Commission, “Advancing manufacturing – Advancing Europe,” Commission Staff Working Document, Brussels, Rep. of the task force on advanced manufacturing for clean production, Mar. 2014.

D.S. Thomas and S.W. Gilbert, “Costs and cost effectiveness of additive manufacturing-a Literature review and discussion,” National Institute of Standards and Technology, US Department of Commerce, Dec. 2014.

G. Urbikain, A. Alvarez, L.N. López de Lacalle, M. Arsuaga, M. A. Alonso and F. Veiga, “A reliable turning process by the early use of a deep simulation model at several manufacturing stages,” Machines, vol.5, no.2, pp.15, 2017.

J. Xu, E. Huang, L. Hsieh, L.H. Lee, Q.-S. Jia and C.-H. Chen, “Simulation optimization in the era of Industrial 4.0 and the Industrial Internet,” J Simulation, vol.10, no.4, pp. 310-320, 2016.

S. Wang, J. Wan, D. Li and C. Zhang, “Implementing smart factory of Industrie 4.0: an outlook,” Int. Journal of Distributed Sensor Networks, vol. 12, no.1, pp. 1-10, 2016.

P. Zheng, H. Wang, Z. Sang, et al., “Smart manufacturing systems for Industry 4.0: conceptual framework, scenarios, and future perspectives,” Front. Mech. Eng., 2018.

H. Cheng, P. Zeng, L. Xue, Z, Shi, P. Wang and H. Yu, “Manufacturing ontology development based on Industry 4.0 demonstration production line,” Third International Conference on Trustworthy Systems and Their Applications(TSA), Sept. 2016.

Deloitte, “Industry 4.0: an introduction”, Rep., Holanda, 2015.

P. Gerbert, M. Lorenz, M. Rusmann, et al., “Industry 4.0: the future of productivity and growth in manufacturing industries,” Rep. The Boston Consulting Group (BCG), German, Apr. 2015.

European Commission. SMEs to the Industry 4.0. (accessed 2017, Apr.). Available:http://s3platform.jrc.ec.europa.eu/sme-integration-to-industry

T. Kaihara, Y. Katsumura, Y. Suginishi and B. Kádár, “Simulation model study for manufacturing effectiveness evaluation in crowdsourced manufacturing,” CIRP Annals – Manufacturing Technology, vol.66, no.1, pp. 445-448, 2017.

A. Khan and K. Turowski,“Perspective on industry 4.0: from challenges to opportunities in production systems,” in Proc. International Conference on Internet of Things and Big Data, Rome, 2016, pp.441–448.

Horst,D.J,Duvoisin,CA,de Almeida,R,“ Additive Manufacturing in Industry 4.0”,International Journal of Engineering and Technology,2018,pp.3-8.

Mourzits,D,Vlachou.E,Zogopoulos.V, “Integrated production and maintenance scheduling through machine monitoring and AR: An Industry 4.0 approach, International Conference of Advances in Production Management,2017,pp.354-362.

Benedictus Rahardjo,Fu-Kwun Wang,Yu-Ping Chang’ “Lean Manufacturing in Industry 4.0: A Smart and sustainable Manufacturing System”, ,Machines, MDPI article 2023,pp.1-17.

Costas, J., Ponte, B., de la Fuente, D., Pino, R., & Puche, J. (2015). Applying Goldratt’s Theory of Constraints to reduce the Bullwhip Effect through agent-based modeling. Expert Systems with Applications, 42(4), 2049–2060. Web.

A comprehensive review of Lean manufacturing using constraints theory with Context to Industry 4.0