Recent developments in manufacturing processes and automation have led to the new industrial revolution termed “Industry 4.0”. Industry 4.0 can be considered as a broad domain which includes: data management, manufacturing competitiveness, production processes and efficiency. The term Industry 4.0 includes a variety of key enabling technologies i.e., cyber physical systems, Internet of Things, artificial intelligence, big data analytics and digital twins which can be considered as the major contributors to automated and digital manufacturing environments. Sustainability can be considered as the core of business strategy which is highlighted in the United Nations (UN) Sustainability 2030 agenda and includes smart manufacturing, energy efficient buildings and low-impact industrialization. Industry 4.0 technologies help to achieve sustainability in business practices. However, very limited studies reported about the extensive reviews on these two research areas. This study uses a systematic literature review approach to find out the current research progress and future research potential of Industry 4.0 technologies to achieve manufacturing sustainability. The role and impact of different Industry 4.0 technologies for manufacturing sustainability is discussed in detail. The findings of this study provide new research scopes and future research directions in different research areas of Industry 4.0 which will be valuable for industry and academia in order to achieve manufacturing sustainability with Industry 4.0 technologies.

Industry 4.0 Technologies for Manufacturing Sustainability: A Systematic Review and Future Research Directions

Since 2011, when the concepts of Industry 4.0 were first announced, this industrial revolution has grown and expanded from some theoretical concepts to real-world applications. Its practicalities can be found in many fields and affect nearly all of us in so many ways. While we are adapting to new changes, adjustments are starting to reveal on national and international levels. It is becoming clear that it is not just new innovations at play, technical advancements, governmental policies and markets have never been so intertwined. Here, we generally describe the concepts of Industry 4.0, explain some new terminologies and challenges for clarity and completeness. The key of this paper is that we summarise over 14 countries’ up-to-date national strategies and plans for Industry 4.0. Some of them are bottom-up, such as Portugal, some top-down, such as Italy, a few like the United States had already been moving in this direction long before 2011. We see governments are tailoring their efforts accordingly, and industries are adapting as well as driving those changes.

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Industry 4.0, a revolution that requires technology and national strategies

Sensors play a crucial role in factory automation in making the system intellectual. Different types of sensors are available as per the suitability and applications; some of them are produced in mass and available in the market at affordable costs. The standard sensor types available are position sensors, pressure sensors, flow sensors, temperature sensors, and force sensors. They are used in many sectors, such as motorsport, medical, industry, aerospace, agriculture, and daily life. The objective of Industry 4.0 is to increase efficiency through automation. Sensors are vital components of Industry 4.0, allowing several transitions such as changes in positions, length, height, external and dislocations in industrial production facilities to be detected, measured, analysed, and processed. Smart factories will also enhance sustainability by tracking real-time output, and automated control systems will minimise potential factory maintenance costs. It can also be seen that digitalisation can improve production mobility, which gives advanced manufacturing firms a competitive advantage. This paper discusses sensors and their various types, along with significant capabilities for manufacturing. The step-by-step working Blocks and Quality Services of Sensors during implementation in Industry 4.0 are elaborated diagrammatically. Finally, we identified thirteen significant applications of sensors for Industry 4.0. Industry 4.0 provides an excellent opportunity for the development of the sensor market across the globe. In Industry 4.0, sensors will enjoy higher acceptance rates and benefit from a fully enabled connecting and data exchange and logistics integration. In the coming years, sensor installations may grow in process management, automated production lines, and digital supply chains.

Significance of sensors for industry 4.0: Roles, capabilities, and applications

Artificial intelligence (AI)-based rotor fault diagnosis (RFD) poses a variety of challenges to the prognostics and health management (PHM) of the Industry 4.0 revolution. Rotor faults have drawn more attention from the AI research community in terms of utilizing fault-specific characteristics in its feature engineering, compared to any other rotating machinery faults. While the rotor faults, specifically structural rotor faults (SRF), have proven to be the root cause of most of the rotating machinery issues, the research in this field largely revolves around bearing and gear faults. Within this scenario, this paper is the first of its kind to attempt to review and define the role of AI in RFD and provides an all-encompassing review of rotor faults for the researchers and academics. In addition, this study is unique in three ways: (i) it emphasizes the use of fault-specific characteristic features with AI, (ii) it is grounded in fault-wise analysis rather than component-wise analysis with appropriate fault categorization, and (iii) it portrays the current research and analysis in accordance with different phases of an AI-based RFD framework. Finally, the section on future research directions is aimed at bridging the gap between a laboratory-based solution and a real-world industrial solution for RFD.

Role of artificial intelligence in rotor fault diagnosis: a comprehensive review

An analysis of process fault diagnosis methods from safety perspectives

The recent advancements in the fields of artificial intelligence (AI) and machine learning (ML) have affected several research fields, leading to improvements that could not have been possible with conventional optimization techniques. Among the sectors where AI/ML enables a plethora of opportunities, industrial manufacturing can expect significant gains from the increased process automation. At the same time, the introduction of the Industrial Internet of Things (IIoT), providing improved wireless connectivity for real-time manufacturing data collection and processing, has resulted in the culmination of the fourth industrial revolution, also known as Industry 4.0. In this survey, we focus on the vital processes of fault detection, prediction and prevention in Industry 4.0 and present recent developments in ML-based solutions. We start by examining various proposed cloud/fog/edge architectures, highlighting their importance for acquiring manufacturing data in order to train the ML algorithms. In addition, as faults might also occur from sources beyond machine degradation, the potential of ML in safeguarding cyber-security is thoroughly discussed. Moreover, a major concern in the Industry 4.0 ecosystem is the role of human operators and workers. Towards this end, a detailed overview of ML-based human–machine interaction techniques is provided, allowing humans to be in-the-loop of the manufacturing processes in a symbiotic manner with minimal errors. Finally, open issues in these relevant fields are given, stimulating further research.

Antonis Hatziefremidis

Papers

Tackling Faults in the Industry 4.0 Era-A Survey of Machine-Learning Solutions and Key Aspects.