Nowadays, industries are emphasizing the implementation of a smart shop floor management method because of different types of problems faced in controlling the production activities in Industry 4.0. ...Several shop floor management methods are currently implemented in the present Industry 4.0 scenario, including lean manufacturing, logistics, Internet of things, smart manufacturing, cyber-physical system, and artificial intelligence. The present research work is focused on the development and Taguchi validation methodology of a data-driven decision-making system using L9 orthogonal array for smart shop floor management based on the relationship between production sustainability and constraints. The proposed system has been validated by a comprehensive investigation of a case of mining machinery manufacturing unit. The result of the investigation revealed that productivity has been enhanced by effective controlling of production activities on the shop floor. Taguchi L9 orthogonal array method of design of experiments is implemented to enhance flexibility for shop floor control and meanwhile minimize the production time due to inefficient operating conditions on the shop floor. Taguchi method was implemented for critical conditions affecting production lead time and resource utilization. The authors have detailed discussion on developing present novel hybrid integration of lean and smart manufacturing approaches to enhance operational excellence in production activities and other complicated manufacturing environment on the shop floor within available resources. The present finding demonstrates that the adopted digital technologies under smart manufacturing with lean manufacturing are found to be cost-effective approach under different environmental conditions. The proposed system has significantly improved the efficiency of production management and operational performance by using smart systems and has proved effective in improving the financial position by making a safer shop floor management approach. In this article, a robust problem-solving system is provided. The present work aims to introduce revolutionary methods for Industry 4.0 that would result in productivity enhancement and beneficial impact on industry persons by improving the smart shop floor management. The study also provides valuable perspective and sustainable guidelines to facilitate industry individuals to implement lean and smart manufacturing for productivity enhancement in the production environment of Industry 4.0.
In industry 4.0, shop floor management teams are increasingly focused on developing an unprecedented strategy to avoid financial losses and address the challenges and problems encountered in ...operations management. In the present scenario, the management teams use various process optimization approaches for operational control, including lean manufacturing, smart manufacturing, the internet of things, and artificial intelligence. The process optimization approach is used to maximize productivity within limited constraints on the shop floor. The present research aims to develop a smart production management system and suggest an efficient process optimization approach to enhancing industrial sustainability by identifying problems and challenges encountered in the complex shop-floor conditions in industry 4.0. The developed production management system has been prepared by classifying the challenges and problems found in the previous research work and organizing brainstorming sessions. The developed management system has been validated by a comprehensive investigation of a case study of an earthmoving machinery manufacturing unit. The analysis showed that the developed system could enhance operation excellence and industrial sustainability in industry 4.0 by optimizing the utilization of resources on the shop floor within limited constraints. The authors of the present article strongly believe that the developed production management system will improve operational excellence and would be beneficial for industry personnel and researchers in controlling operations management in shop floor management of heavy machinery manufacturing, including industry 4.0.
