Industry 4.0 for SMEs: Challenges, Opportunities and Requirements

Preface
Contents
Notes on Contributors
List of Figures
List of Tables
Part I Introduction to Industry 4.0 for SMEs
1 SME 4.0: The Role of Small- and Medium-Sized Enterprises in the Digital Transformation
	1.1	Introduction
	1.2	Industry 4.0 as the Fourth Industrial Revolution
		1.2.1	Origin and Characterization of Industry 4.0
		1.2.2	Industry 4.0—A Challenge for Europe and Beyond
	1.3	The Contribution of Small and Medium Enterprises to Economic Development
		1.3.1	The Role of SMEs in the European Economy
		1.3.2	The Role of SMEs in the United States
		1.3.3	The Role of SMEs in Asia
		1.3.4	The Role of SMEs in the World
	1.4	Current State of the Transition of Industry 4.0 to SMEs
		1.4.1	State of the Art of Industry 4.0 for SMEs in Scientific Literature
		1.4.2	Current EU Research Initiatives on Industry 4.0 for SMEs
		1.4.3	Summary of the State-of-the-Art Analysis
	1.5	SME 4.0—Industry 4.0 for SMEs
		1.5.1	“SME 4.0” Project Key Data and Objectives
		1.5.2	Project Structure
		1.5.3	Research Methodology in the First Project Phase
	1.6	Conclusion and Structure of the Book
	References
Part II Industry 4.0 Concepts for Smart Manufacturing in SMEs
2 SME Requirements and Guidelines for the Design of Smart and Highly Adaptable Manufacturing Systems
	2.1	Introduction
	2.2	Background and Literature Review
		2.2.1	Industry 4.0—The Fourth Industrial Revolution
		2.2.2	State of the Art in the Introduction of Smart and Highly Adaptable Manufacturing Systems in SMEs
	2.3	Problem Formulation
	2.4	Research Methodology
	2.5	Analysis of Requirements for SME 4.0 Manufacturing Systems and Coarse Design Guidelines
		2.5.1	Collection of User Needs Through an Explorative Study
		2.5.2	Thematic Clustering and Categorization of Inputs
		2.5.3	Reverse Engineering of Inputs Categorized as DPs and PVs
		2.5.4	Final List of Functional Requirements and Constraints Regarding the Introduction of Industry 4.0 in SMEs
		2.5.5	Derivation of Coarse Design Guidelines for Smart Manufacturing in SMEs
	2.6	Discussion
	2.7	Conclusions
	References
3 Implementation of Industrial Internet of Things and Cyber-Physical Systems in SMEs for Distributed and Service-Oriented Control
	3.1	Introduction
	3.2	Fundamentals of Connectivity
		3.2.1	The OSI Model
		3.2.2	CPS Architecture
		3.2.3	The Concept of Interoperability
		3.2.4	Loosely Coupled Systems and SOA
		3.2.5	The Publish and Subscribe Pattern
		3.2.6	Service Discovery, Zero Configuration, and Plug-and-Play/Work Networks
		3.2.7	Ethernet-Based Connectivity Technologies for SME
	3.3	The Integration Drivers
		3.3.1	Organizational Drivers
		3.3.2	Technical Drivers
	3.4	Connectivity Architecture
		3.4.1	Ethernet-Based Automation System
		3.4.2	A Layered Design for Manufacturing Service Bus
		3.4.3	Physical and Logical Network Topologies of the MSB
	3.5	Case Study
		3.5.1	The Smart Mini Factory
		3.5.2	Design of the Manufacturing Service Bus
		3.5.3	Connectivity Framework Gateways
		3.5.4	The ROS Protocol
	3.6	Conclusions
	References
4 The Opportunities and Challenges of SME Manufacturing Automation: Safety and Ergonomics in Human–Robot Collaboration
	4.1	Introduction
		4.1.1	Introduction to Industrial Collaborative Robotics
		4.1.2	Main Occupational Health and Safety Concepts
		4.1.3	Occupational Health and Safety Standards
		4.1.4	Introduction to Industrial Robot Safety
	4.2	Fundamentals of Occupational Safety in Industrial Human–Robot Interaction
		4.2.1	Mechanical Risk Analysis in Industrial Robotics: Traditional Versus Collaborative Robotics
		4.2.2	Main Safety Standards for Industrial Collaborative Robotics
		4.2.3	Technical Specification ISO TS 15066 (2016) and Collaborative Operations
		4.2.4	Nature of Human–Robot Contacts
	4.3	Human-Centric Design and Ergonomics
		4.3.1	Risk Factors and Musculoskeletal Disorders
		4.3.2	Main Standards on Physical Ergonomics
		4.3.3	Ergonomics in Human–Robot Collaboration
	4.4	Discussion About Potential and Challenges in Safety and Ergonomics in Human–Robot Collaboration
		4.4.1	Main Technological Research Areas of Interest
		4.4.2	Main Organizational Research Areas of Interest
	4.5	Conclusions
	References
Part III Industry 4.0 Concepts for Smart Logistics in SMEs
5 Requirement Analysis for the Design of Smart Logistics in SMEs
	5.1	Introduction
	5.2	Problem Formulation
	5.3	Related Work
	5.4	Research Design/Methodology
	5.5	Hypothesis of Requirements for Smart Logistics in SMEs
		5.5.1	Lean and Agility
		5.5.2	Real-Time Status
		5.5.3	Digitization, Connectivity, and Network
		5.5.4	Tracking, PPC, and WMS
		5.5.5	Culture, People, and Implementation
		5.5.6	Security and Safety
		5.5.7	Ease of Use
		5.5.8	Transportation
		5.5.9	Automation
	5.6	Creativity and Viability Through Axiomatic Design
	5.7	Conclusions and Outlook
	References
6 Consistent Identification and Traceability of Objects as an Enabler for Automation in the Steel Processing Industry
	6.1	Introduction
	6.2	Background and Literature Review of Identification and Traceability
		6.2.1	Labeling Type and Content
		6.2.2	Labeling Method
	6.3	Problem Formulation
	6.4	Methods/Methodology
		6.4.1	Developing a Traceability Model
		6.4.2	Traceability Issues in Process Industries
	6.5	A Case—Tracing Continuous Flow in Process Industries
		6.5.1	Initial Situation and Project Steps
		6.5.2	Evaluation of Proposed Solutions
	6.6	Discussion and Conclusions
	References
7 State-of-the-Art Analysis of the Usage and Potential of Automation in Logistics
	7.1	Introduction—Automation in Production Logistics
	7.2	Problem Formulation and Methods/Methodology
	7.3	Enablers of Automation in Logistics
		7.3.1	Identification Technologies for Automation
		7.3.2	Technological Concepts for Automation
	7.4	Discussion of Automation Approaches
		7.4.1	Agent-Based Automation Through Enhanced Process Control
		7.4.2	Automated Guided Vehicles (AGVs) and Robots in Logistics Systems
		7.4.3	Conveyor Belts and Sorting Systems
		7.4.4	Automation Through Augmented Reality (AR)
		7.4.5	Automation Through Modularization Strategies
	7.5	A Case—Conveyor Belts and Sorting Systems Case Study: Medium-Sized Logistics Service Provider in Thailand
	7.6	Discussion, Suggestions, and Implications
	References
Part IV Industry 4.0 Managerial, Organizational and Implementation Issues
8 Development of an Organizational Maturity Model in Terms of Mass Customization
	8.1	Introduction
	8.2	Literature Review
	8.3	Problem Description
	8.4	Methodology
	8.5	Proposed Approaches and Solutions
		8.5.1	Development of QMM
		8.5.2	Application of the QMM
		8.5.3	Identification of the Key Requirement of SMEs
	8.6	Maturity Model of Organizational Capabilities for Mass Customized Manufacturing
		8.6.1	Additional Requirements of the Maturity Model
		8.6.2	Description of the Main Features of the Maturity Model
			8.6.2.1 Product Modularity and Process Modularity
			8.6.2.2 Integration of Product Configurator into Process Planning
	8.7	Future Research Work and Conclusions
	Appendix 8.1
	Appendix 8.2
	Appendix 8.3
	Appendix 8.4
	References
9 Implementing Industry 4.0 in SMEs: A Focus Group Study on Organizational Requirements
	9.1	Introduction
	9.2	Background
		9.2.1	Organizational Barriers to Industry 4.0 Implementation
		9.2.2	Barriers to Innovation
	9.3	Problem Formulation
	9.4	Methodology
		9.4.1	Focus Group Method
		9.4.2	Sample Selection and Data Collection
		9.4.3	Data Analysis
	9.5	Results
	9.6	Discussion
	9.7	Conclusions
	References
10 Smart SME 4.0 Implementation Toolkit
	10.1	Introduction
	10.2	Background and Literature Review
		10.2.1 Information Technology
			10.2.1.1 Equipment Infrastructure
			10.2.1.2 IT System
			10.2.1.3 Information Sharing
			10.2.1.4 Cloud Based
		10.2.2 Production and Operations
			10.2.2.1 Innovation Management
			10.2.2.2 Data Analytics
			10.2.2.3 Horizontal/Vertical Data Integration
			10.2.2.4 Expert Systems
		10.2.3 Automation
			10.2.3.1 OEE Equipment Effectiveness
			10.2.3.2 Man-Machine Interaction
			10.2.3.3 Autonomous Process
			10.2.3.4 M2M Machine Connectivity
		10.2.4 Human Resource
			10.2.4.1 Technical
			10.2.4.2 Non-Technical
	10.3	Problem Formulation
	10.4	Methodology
	10.5	Problem Solution
		10.5.1 SMEs 4.0 for Make-to-Order Snack Factory
		10.5.2 SMEs 4.0 for Service Industry—A Coffee Shop
		10.5.3 SMEs 4.0 for Small Fabrication Company
		10.5.4 SMEs 4.0 for Multinational SMEs
	10.6	Discussion
	10.7	Conclusions
	References
Part V Case Studies and Methodical Tools for Implementing Industry 4.0 in SMEs
11 The Digitization of Quality Control Operations with Cloud Platform Computing Technologies
	11.1	Introduction
	11.2	Background and Literature Review
	11.3	Problem Formulation and Methodology
	11.4	Problem Solution
		11.4.1	Quality Control Objects
		11.4.2	Data Acquisition During Quality Control Process
			11.4.2.1 Data Extraction from Vision Systems
			11.4.2.2 Data Extraction from RFID System
		11.4.3	Data Storing and Analyzing Using Cloud Platform
		11.4.4	Digital Twin with Simulation and Virtual Reality
	11.5	Discussion
	11.6	Conclusions
	References
12 Implementation of a Laboratory Case Study for Intuitive Collaboration Between Man and Machine in SME Assembly
	12.1	Introduction
	12.2	Theoretical Background
	12.3	Methodology for the Evaluation of Human–Robot Task Allocation
		12.3.1	Technical Evaluation
		12.3.2	Physical Ergonomic Evaluation
		12.3.3	Product/Process Quality Evaluation
		12.3.4	Economic Evaluation
		12.3.5	Final Evaluation
	12.4	Application of Intuitive Human–Robot Interaction in the Smart Mini Factory Lab
		12.4.1	Introduction to the Smart Mini Factory
		12.4.2	Case Study Description
		12.4.3	Pneumatic Cylinder Collaborative Assembly
		12.4.4	Case Study Evaluation
	12.5	Discussion and Hypothesis for Future Work
		12.5.1	Task Allocation Methodology: Future Developments
		12.5.2	Real-Time Allocation for Assembly
		12.5.3	Cell Digitalization
		12.5.4	Situational Awareness
	12.6	Conclusions
	References
13 Axiomatic Design for Products, Processes, and Systems
	13.1	The Axioms and Engineering Design as a Scientific Discipline
		13.1.1 The Axioms
		13.1.2 Three Parts and Six Elements
		13.1.3 Axiom One: Maintain Independence
		13.1.4 Axiom Two: Minimize the Information Content
	13.2	Structures
		13.2.1 Design Domains and Constraints—Lateral Decompositions
			13.2.1.1 Customer Needs (CNs)
			13.2.1.2 Functional Requirements (FRs)
			13.2.1.3 Design Parameters (DPs)
			13.2.1.4 Process Variables (PVs)
			13.2.1.5 Constraints (Cs)
		13.2.2 Design Hierarchies—Vertical Decomposition
	13.3	The Design Process
		13.3.1 Zigzagging Decomposition
			13.3.1.1 Checking for Independence (Axiom One)
			13.3.1.2 Decomposition Themes
			13.3.1.3 Metrics and Equations
		13.3.2 Physical Integration
	13.4	Additional Applications and Industry 4.0
		13.4.1 Analyzing Existing Designs
		13.4.2 Recognizing Opportunities for Creativity and Innovation
		13.4.3 Application for Industry 4.0
	13.5	Concluding Remarks
	References
Index