IoT Energy Retrofit and the Connection of Legacy Machines Inside the Industry 4.0 Concept

Lima, Fábio; Massote, Alexandre Augusto; Maia, Rodrigo Filev

doi:10.1109/iecon.2019.8927799

Cited by 25 publications

(24 citation statements)

References 22 publications

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“…Kianian et al [6] proposed an LCC analysis for the manufacturing process of cylindrical gear. Gontarz et al [7] based their work on an economic analysis of the retrofitting of a machine tool component, and Lima et al [8] developed a cost-effective retrofitting solution for SMEs, which are often excluded from the Industry 4.0 paradigm.…”

Section: Methodologies For Assessing the Sustainability Of Production...mentioning

confidence: 99%

Machine Tool Transition from Industry 3.0 to 4.0: A Comparison between Old Machine Retrofitting and the Purchase of New Machines from a Triple Bottom Line Perspective

2021

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The emerging scenario designed by digital technologies connected to Industry 4.0 is pushing towards increasingly sustainable companies. Access to the multiple benefits of digitalization (such as increased productivity, flexibility, efficiency, quality, lower consumption of resources, and the improvement of worker safety) is possible by purchasing new-generation machinery. However, thanks to smart retrofitting processes, companies can extend the shelf life of machinery without replacing it entirely. This work aims to present a framework to assess the sustainability of implementing a smart retrofitting process in old machines as an alternative to replacement from a triple bottom line (economic, environmental, and social) perspective. Due to the multidimensional and multidisciplinary variables that the proposed framework must consider, a multicriteria decision-making process is developed to identify the best transition solution from Industry 3.0 to 4.0. Then, we analyze a case study in which, thanks to the previously proposed methodology, two types of smart retrofitting on a column drill are compared with three replacement options for the same machine tool. In conclusion, the case study shows that retrofitting in the context of Industry 4.0 (or smart retrofitting), despite its high acquisition cost, is the best solution in terms of sustainability, and that this is because the smart retrofitting solution not only positively influences all parameters of digitization but also has a strong impact on the safety criterion.

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Section: Methodologies For Assessing the Sustainability Of Production...mentioning

confidence: 99%

Machine Tool Transition from Industry 3.0 to 4.0: A Comparison between Old Machine Retrofitting and the Purchase of New Machines from a Triple Bottom Line Perspective

2021

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“…This not only eliminates "isolated islands" within a production line but also increases the transparency of the entire production flow which can be streamlined to be more stable and effective. Based on an IoT platform, the energy consumption of each machine on the shop floor can provide feedback on the operational condition of the whole production system to support decision making [14].…”

Section: Legacy Machinesmentioning

confidence: 99%

The implementation of Industry 4.0 in manufacturing: from lean manufacturing to product design

Huang

Jowers

Kent

et al. 2022

Int J Adv Manuf Technol

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With the emergence of Industry 4.0, digitalization and intelligent manufacturing are vital to ensure competitivity, especially for manufacturers reliant on legacy machines. Upgrading legacy machines with cyber physical technology under Industry 4.0 frameworks can enable connection of these machines to existing IoT networks to allow the sharing and exchange of production information. In this paper, a legacy machine used in sheet metal folding operations is upgraded by integrating switch sensors which provide detailed data on the machine status to stakeholders, enabling in-depth analysis of the production activity before and after the implementation of lean manufacturing methods. Furthermore, it is shown that the data collected can be applied to conduct dynamic value stream mapping (DVSM) in near real time to provide deeper level insight into manufacturing processes. More detailed mapping enables identification of wastes involved with labour and design. Therefore, an innovative graphical technique is proposed to improve the flattened pattern to reduce manual handling and ease bottlenecks identified by VSM. From the collected VSM data, a leanness measure was established to provide objective and quantitative evaluation of the process performance.

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“…For example, Kostolani et al [92] carried out a specific implementation using an industrial gateway called Siemen's Simatic IoT 2040 to collect, transform, and process data and to enable remote control of machinery. A similar study by Lima et al [86] conducted on CNC machinery used IoT devices such as energy sensors, switches, and gateways to monitor energy data in realtime. Givehchi et al [2] proposed an interoperability layer that accesses field-level data through a commercial gateway called the Raspberry Pi.…”

Section: Iot Hardware-based Solutionsmentioning

confidence: 99%

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

2022

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Industry 4.0 technologies and digitalised processes are essential for implementing smart manufacturing within vertically and horizontally integrated production environments. These technologies offer new ways to generate revenue from data-driven services and enable predictive maintenance based on real-time data analytics. They also provide autonomous manufacturing scheduling and resource allocation facilitated by cloud computing technologies and the industrial Internet of Things (IoT). Although the fourth industrial revolution has been underway for more than a decade, the manufacturing sector is still grappling with the process of upgrading manufacturing systems and processes to Industry 4.0-conforming technologies and standards. Small and medium enterprises (SMEs) in particular, cannot always afford to replace their legacy systems with state-of-the-art machines but must look for financially viable alternatives. One such alternative is retrofitting, whereby old manufacturing systems are upgraded with sensors and IoT components to integrate them into a digital workflows across an enterprise. Unfortunately, to date, the scope and systematic process of legacy system retrofitting, and integration are not well understood and currently represent a large gap in the literature. In this article, the authors present an in-depth systematic review of case studies and available literature on legacy system retrofitting. A total of 32 papers met the selection criteria and were particularly relevant to the topic. Three digital retrofitting approaches are identified and compared. The results include insights common technologies used in retrofitting, hardware and software components typically required, and suitable communication protocols for establishing interoperability across the enterprise. These form an initial basis for a theoretical decision-making framework and associated retrofitting guide tool to be developed.

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IoT Energy Retrofit and the Connection of Legacy Machines Inside the Industry 4.0 Concept

Cited by 25 publications

References 22 publications

Machine Tool Transition from Industry 3.0 to 4.0: A Comparison between Old Machine Retrofitting and the Purchase of New Machines from a Triple Bottom Line Perspective

Machine Tool Transition from Industry 3.0 to 4.0: A Comparison between Old Machine Retrofitting and the Purchase of New Machines from a Triple Bottom Line Perspective

The implementation of Industry 4.0 in manufacturing: from lean manufacturing to product design

Industry 4.0: a systematic review of legacy manufacturing system digital retrofitting

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