Sajjad Khan

Industry 4.0 allows for greater flexibility in production processes so that products can be customized (i.e., mass customization). Innovative production techniques in an industrial liquid/yogurt filling machine (YFM) improved efficiency in the beverage industry. In this study, we have introduced the second phase designed control architecture of our YFM based on the concepts of industry 4.0 incorporating an NFC platform for improving customer satisfaction. Especially during this pandemic period, wireless technologies have been ubiquitous and pervasive for customized products. The basic components of the YFM have been described. High-level control architecture programmed fully automated filling operations, and the design stage of the development of a PFC-based controller for the YFM is elaborated. For the evaluation of the proposed control system, the operations of the electric/pneumatic input devices and actuators were simulated on FluidSIM-MecLab. The results of the simulation verify the design logic of the PFC-based controller. Comparisons were made between different production types using the developing YFM. A complex learning environment replicating a real production system to understand, learn, and apply modern manufacturing approaches has been developed. Through the creation of this YFM, the academic environment and industrial applications are combined. Consequently, the problem verification is becoming more realistic and more efficient than online (trial and error) automation programming.

The movement to digitally transform Saudi Arabia in all sectors has already begun under the “Vision 2030” program. Consequently, renovating and standardizing production and manufacturing industries to compete with global challenges is essential. The fourth industrial revolution (Industry 4.0) triggered by the development of information and communications technologies (ICT) provides a baseline for smart automation, using decentralized control and smart connectivity (e.g., Internet of Things). Industrial engineering graduates need to have acquaintance with this industrial digital revolution. Several industries where the spirit of Industry 4.0 has been embraced and have already implemented these ideas yielded gains. In this paper, a roadmap containing an academic term course based on the concept of Industry 4.0, which our engineering graduates passed through, is presented. At first, an orientation program to students elaborating on the Industry 4.0 concept, its main pillars, the importance of event-driven execution, and smart product manufacturing techniques. Then, various tasks in developing a learning factory were split and assigned among student groups. Finally, the evaluation of student potential in incorporating the Industry 4.0 concept was analyzed. This methodology led to their professional skill development and promoted students’ innovative ideas for the manufacturing sector.

In recent decades, production in high-volume/low-variety batches is replaced with low-volume/high-variety production type. This type of production demands excessive flows of both material and information. Recent advances in information and communication technologies (ICT), together with the concept of cyber-psychical system (CPS) enable the concept of Industry 4.0 (I4.0). In this paper, the performance of I4.0 related equipment implementation is presented in iterative assembly line balancing (ALB) process of a gearbox assembly line. Largest candidate rule method through spreadsheet simulation was used for tasks reallocations, with the objective to minimize the cycle time when the number of stations is fixed. Utilization of human analysts using snap back method for manual data gathering process still shown advantage over I4.0 equipment utilization in manual ALB. The assembly process is performed in the learning factory environment, and it is considered as very close to real industry process. The major conclusion is that I4.0 is excellent in process data monitoring and product tracking, but activities to be performed to effectively exploit I4.0 is demanding for task reallocations during the balancing procedure. Nevertheless, future enhancements of I4.0 system are listed to bridge this gap and to increase I4.0 system usefulness in the manual assembly line balancing process.