Emerging Technologies-Driven Operations Management for Flexible Manufacturing Systems on the Shop Floor
DOI:
https://doi.org/10.31181/rme494Keywords:
Advanced Industrial Environment, Industry 4.0, Internet of Things, Operations Management, Resource Utilization, Smart ManufacturingAbstract
Industry professionals are worried about resource utilization in operations management. Industry personnel use several strategies and advanced techniques to improve resource use by monitoring production activities. The advanced approach helps tackle the issues faced in the shop-floor operational scenario. In the current scenario, industry professionals are seeking a strategic approach to enhance operational outcomes while maximising resource contribution. The present study develops an innovative in the current-edge era. The study develops a novel architecture for controlling operational performance within limited constraints using advanced techniques. The strategy helps maintain and optimise operations by simultaneously monitoring workforce, machinery, and workflow performance in real time. The strategy uses emerging technologies for operational data management to achieve operational management excellence. The study showed that advanced techniques provide a human-centric approach to problem-solving, key to monitoring operations workflows and enhancing work-floor outcomes. The present study can provide a key to decision-making and resource utilisation for industry personnel in the current advanced operational monitoring environment. Operations managers can access the required data more efficiently and implement an appropriate action plan to eliminate potential failure points on the shop floor. The study helps industry professionals make decisions about operational and resource performance in a flexible manufacturing environment.
References
Arora, M., Ahmad, V., Kumar, R., & Singh, R. (2025). The impact of Industry 4.0 technologies on operational excellence methods: Application of fuzzy TOPSIS. Engineering Management Journal, 1-12. https://doi.org/10.1080/10429247.2024.2443703
Aytug, H., Lawley, M. A., McKay, K., Mohan, S., & Uzsoy, R. (2005). Executing production schedules in the face of uncertainties: A review and some future directions. European Journal of Operational Research, 161(1), 86-110. https://doi.org/10.1016/j.ejor.2003.08.027
Bag, S., Yadav, G., Dhamija, P., & Kataria, K. K. (2021). Key resources for industry 4.0 adoption and its effect on sustainable production and circular economy: An empirical study. Journal of Cleaner Production, 281, 125233. https://doi.org/10.1016/j.jclepro.2020.125233
Beliatis, M. J., Jensen, K., Ellegaard, L., Aagaard, A., & Presser, M. (2021). Next generation industrial IoT digitalization for traceability in metal manufacturing industry: A case study of industry 4.0. Electronics, 10(5), 628. https://doi.org/10.3390/electronics10050628
Bristol-Alagbariya, B., Ayanponle, O., & Ogedengbe, D. E. (2022). Developing and implementing advanced performance management systems for enhanced organizational productivity. World Journal of Advanced Science and Technology, 2(1), 39-46. https://doi.org/10.53346/wjast.2022.2.1.0037
Chan, F., Wong, T., & Chan, L. (2006). Flexible job-shop scheduling problem under resource constraints. International Journal of Production Research, 44(11), 2071-2089. https://doi.org/10.1080/00207540500386012
Chen, B., Wan, J., Shu, L., Li, P., Mukherjee, M., & Yin, B. (2017). Smart factory of industry 4.0: Key technologies, application case, and challenges. IEEE Access, 6, 6505-6519. https://doi.org/10.1109/ACCESS.2017.2783682
Cheng, J., Chen, W., Tao, F., & Lin, C.-L. (2018). Industrial IoT in 5G environment towards smart manufacturing. Journal of Industrial Information Integration, 10, 10-19. https://doi.org/10.1016/j.jii.2018.04.001
Dalenogare, L. S., Benitez, G. B., Ayala, N. F., & Frank, A. G. (2018). The expected contribution of Industry 4.0 technologies for industrial performance. International Journal of Production Economics, 204, 383-394. https://doi.org/10.1016/j.ijpe.2018.08.019
Enrique, D. V., Marcon, É., Charrua-Santos, F., & Frank, A. G. (2022). Industry 4.0 enabling manufacturing flexibility: technology contributions to individual resource and shop floor flexibility. Journal of Manufacturing Technology Management, 33(5), 853-875. https://doi.org/10.1108/JMTM-08-2021-0312
Esmaeilian, B., Sarkis, J., Lewis, K., & Behdad, S. (2020). Blockchain for the future of sustainable supply chain management in Industry 4.0. Resources, conservation and recycling, 163, 105064. https://doi.org/10.1016/j.resconrec.2020.105064
Ferrer, B. R., Mohammed, W. M., Lastra, J. L. M., Villalonga, A., Beruvides, G., Castaño, F., & Haber, R. E. (2018). Towards the adoption of cyber-physical systems of systems paradigm in smart manufacturing environments. In 2018 IEEE 16th International Conference on Industrial Informatics (INDIN) (pp. 792-799). IEEE. https://doi.org/10.1109/INDIN.2018.8472061
Frontoni, E., Loncarski, J., Pierdicca, R., Bernardini, M., & Sasso, M. (2018). Cyber physical systems for industry 4.0: Towards real time virtual reality in smart manufacturing. In International Conference on Augmented Reality, Virtual Reality and Computer Graphics (pp. 422-434). Springer. https://doi.org/10.1007/978-3-319-95282-6_31
Gomaa, A. H. (2025). Lean 4.0: A Strategic Roadmap for Operational Excellence and Innovation in Smart Manufacturing. International Journal of Emerging Science and Engineering (IJESE), 13(4), 1-14. https://doi.org/10.35940/ijese.D2592.13050425
Grassi, A., Guizzi, G., Santillo, L. C., & Vespoli, S. (2021). Assessing the performances of a novel decentralised scheduling approach in Industry 4.0 and cloud manufacturing contexts. International Journal of Production Research, 59(20), 6034-6053. https://doi.org/10.1080/00207543.2020.1799105
Guo, D., Li, M., Zhong, R., & Huang, G. Q. (2021). Graduation Intelligent Manufacturing System (GiMS): an Industry 4.0 paradigm for production and operations management. Industrial Management & Data Systems, 121(1), 86-98. https://doi.org/10.1108/IMDS-08-2020-0489
Khan, S. A., Kaviani, M. A., J. Galli, B., & Ishtiaq, P. (2019). Application of continuous improvement techniques to improve organization performance: A case study. International Journal of Lean Six Sigma, 10(2), 542-565. https://doi.org/10.1108/IJLSS-05-2017-0048
Khan, S. I., Kaur, C., Al Ansari, M. S., Muda, I., Borda, R. F. C., & Bala, B. K. (2025). Implementation of cloud based IoT technology in manufacturing industry for smart control of manufacturing process. International Journal on Interactive Design and Manufacturing (IJIDeM), 19(2), 773-785. https://doi.org/10.1007/s12008-023-01366-w
Khosroniya, M., Hosnavi, R., & Zahedi, M. R. (2024). Enhancing operational performance in Industry 4.0: The mediating role of total quality management and total productive maintenance at Zarharan Industrial Complex. International journal of industrial engineering and operational research, 6(1), 96-122. https://doi.org/10.22034/ijieor.v6i1.94
Kurdve, M., & Bellgran, M. (2021). Green lean operationalisation of the circular economy concept on production shop floor level. Journal of Cleaner Production, 278, 123223. https://doi.org/10.1016/j.jclepro.2020.123223
Lee, J., Azamfar, M., & Bagheri, B. (2021). A unified digital twin framework for shop floor design in industry 4.0 manufacturing systems. Manufacturing Letters, 27, 87-91. https://doi.org/10.1016/j.mfglet.2021.01.005
Leusin, M. E., Frazzon, E. M., Uriona Maldonado, M., Kück, M., & Freitag, M. (2018). Solving the job-shop scheduling problem in the industry 4.0 era. Technologies, 6(4), 107. https://doi.org/10.3390/technologies6040107
Liu, M., Sun, M., Zhang, X., Ge, M., & Hu, J. (2025). Real-time shop floor operations improvement based on dynamic value stream mapping and hybrid simulation in Industry 4.0: an economic perspective. International Journal of Production Research, 1-25. https://doi.org/10.1080/00207543.2025.2487921
Miragliotta, G., Ordieres, J., & Shrouf, F. (2014). Smart Factories in Industry 4.0: a review of the concept and of Energy Management approaches in Porduction based on the Internet of Things. In IEEE International conference on Industrial, Engineering and Engineering Management (pp. 697-701). https://doi.org/10.1109/IEEM.2014.7058728
Mittal, S., Khan, M. A., Purohit, J. K., Menon, K., Romero, D., & Wuest, T. (2020). A smart manufacturing adoption framework for SMEs. International Journal of Production Research, 58(5), 1555-1573. https://doi.org/10.1080/00207543.2019.1661540
Monek, G. D., & Fischer, S. (2023). DES and IIoT fusion approach towards real-time synchronization of physical and digital components in manufacturing processes. Reports in Mechanical Engineering, 4(1), 161-174. https://doi.org/10.31181/rme040115092023m
Mourtzis, D., & Vlachou, E. (2018). A cloud-based cyber-physical system for adaptive shop-floor scheduling and condition-based maintenance. Journal of manufacturing systems, 47, 179-198. https://doi.org/10.1016/j.jmsy.2018.05.008
Mourtzis, D., Vlachou, E., Zogopoulos, V., & Fotini, X. (2017). Integrated production and maintenance scheduling through machine monitoring and augmented reality: An Industry 4.0 approach. In IFIP international conference on advances in production management systems (pp. 354-362). Springer. https://doi.org/10.1007/978-3-319-66923-6_42
Mzili, T., Mzili, I., Riffi, M. E., Pamucar, D., Kurdi, M., & Ali, A. H. (2023). Optimizing production scheduling with the spotted hyena algorithm: A novel approach to the flow shop problem. Reports in Mechanical Engineering, 4(1), 90-103. https://doi.org/10.31181/rme040116072023m
Ozbiltekin-Pala, M., Kazancoglu, Y., Kumar, A., Garza-Reyes, J. A., & Luthra, S. (2024). Analyzing critical factors of strategic alignment between operational excellence and Industry 4.0 technologies in smart manufacturing. The TQM Journal, 36(1), 161-177. https://doi.org/10.1108/TQM-07-2022-0232
Peças, P., Encarnação, J., Gambôa, M., Sampayo, M., & Jorge, D. (2021). Pdca 4.0: A new conceptual approach for continuous improvement in the industry 4.0 paradigm. Applied Sciences, 11(16), 7671. https://doi.org/10.3390/app11167671
Qu, T., Yang, H., Huang, G. Q., Zhang, Y., Luo, H., & Qin, W. (2012). A case of implementing RFID-based real-time shop-floor material management for household electrical appliance manufacturers. Journal of Intelligent Manufacturing, 23(6), 2343-2356. https://doi.org/10.1007/s10845-010-0476-2
Ren, S., Zhao, X., Huang, B., Wang, Z., & Song, X. (2019). A framework for shopfloor material delivery based on real-time manufacturing big data. Journal of Ambient Intelligence and Humanized Computing, 10(3), 1093-1108. https://doi.org/10.1007/s12652-018-1017-7
Saabye, H., & Powell, D. J. (2024). Fostering insights and improvements from IIoT systems at the shop floor: a case of industry 4.0 and lean complementarity enabled by action learning. International Journal of Lean Six Sigma, 15(5), 968-996. https://doi.org/10.1108/IJLSS-01-2022-0017
Saqlain, M., Piao, M., Shim, Y., & Lee, J. Y. (2019). Framework of an IoT-based industrial data management for smart manufacturing. Journal of Sensor and Actuator Networks, 8(2), 25. https://doi.org/10.3390/jsan8020025
Shahin, M., Chen, F. F., Bouzary, H., & Krishnaiyer, K. (2020). Integration of Lean practices and Industry 4.0 technologies: smart manufacturing for next-generation enterprises. The International Journal of Advanced Manufacturing Technology, 107(5), 2927-2936. https://doi.org/10.1007/s00170-020-05124-0
Tao, F., Qi, Q., Liu, A., & Kusiak, A. (2018). Data-driven smart manufacturing. Journal of manufacturing systems, 48, 157-169. https://doi.org/10.1016/j.jmsy.2018.01.006
Terrazas, G., Ferry, N., & Ratchev, S. (2019). A cloud-based framework for shop floor big data management and elastic computing analytics. Computers in Industry, 109, 204-214. https://doi.org/10.1016/j.compind.2019.03.005
Tortorella, G. L., Fogliatto, F. S., Cauchick-Miguel, P. A., Kurnia, S., & Jurburg, D. (2021). Integration of industry 4.0 technologies into total productive maintenance practices. International Journal of Production Economics, 240, 108224. https://doi.org/10.1016/j.ijpe.2021.108224
Tripathi, V., & Bhadauria, A. (2025). Leveraging the competency of condition monitoring system for achieving excellence in operations management. Discover Sustainability, 6(1), 452. https://doi.org/10.1007/s43621-025-01285-8
Tripathi, V., Chattopadhyaya, S., Mukhopadhyay, A. K., Sharma, S., Li, C., Singh, S., Hussan, W. U., Salah, B., Saleem, W., & Mohamed, A. (2022). A sustainable productive method for enhancing operational excellence in shop floor management for industry 4.0 using hybrid integration of lean and smart manufacturing: An ingenious case study. Sustainability, 14(12), 7452. https://doi.org/10.3390/su14127452
Tripathi, V., Garg, D., Di Bona, G., & Silvestri, A. (2025). Leveraging the Power of Human Resource Management Practices for Workforce Empowerment in SMEs on the Shop Floor: A Study on Exploring and Resolving Issues in Operations Management. Sustainability, 17(15), 6928. https://doi.org/10.3390/su17156928
Tripathi, V., Saraswat, S., & Gautam, G. D. (2022). Improvement in shop floor management using ANN coupled with VSM: a case study. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 236(10), 5651-5662. https://doi.org/10.1177/09544062211062062
Vatankhah Barenji, A., Liu, X., Guo, H., & Li, Z. (2021). A digital twin-driven approach towards smart manufacturing: reduced energy consumption for a robotic cell. International Journal of Computer Integrated Manufacturing, 34(7-8), 844-859. https://doi.org/10.1080/0951192X.2020.1775297
Wang, M., Altaf, M. S., Al-Hussein, M., & Ma, Y. (2020). Framework for an IoT-based shop floor material management system for panelized homebuilding. International journal of construction management, 20(2), 130-145. https://doi.org/10.1080/15623599.2018.1484554
Wang, S., Wan, J., Zhang, D., Li, D., & Zhang, C. (2016). Towards smart factory for industry 4.0: a self-organized multi-agent system with big data based feedback and coordination. Computer networks, 101, 158-168. https://doi.org/10.1016/j.comnet.2015.12.017
Yang, W., & Takakuwa, S. (2017). Simulation-based dynamic shop floor scheduling for a flexible manufacturing system in the industry 4.0 environment. In 2017 Winter Simulation Conference (WSC) (pp. 3908-3916). IEEE. https://doi.org/10.1109/WSC.2017.8248101
Zhang, J., Liu, J., Zhuang, C., Guo, H., & Ma, H. (2024). A data-driven smart management and control framework for a digital twin shop floor with multi-variety multi-batch production. The International Journal of Advanced Manufacturing Technology, 131(11), 5553-5569. https://doi.org/10.1007/s00170-023-10815-5
Zhang, X., & Ming, X. (2021). An implementation for Smart Manufacturing Information System (SMIS) from an industrial practice survey. Computers & Industrial Engineering, 151, 106938. https://doi.org/10.1016/j.cie.2020.106938
Zhong, R. Y., Dai, Q., Qu, T., Hu, G., & Huang, G. Q. (2013). RFID-enabled real-time manufacturing execution system for mass-customization production. Robotics and Computer-Integrated Manufacturing, 29(2), 283-292. https://doi.org/10.1016/j.rcim.2012.08.001
Downloads
Published
Issue
Section
License
Copyright (c) 2025 Reports in Mechanical Engineering
This work is licensed under a Creative Commons Attribution 4.0 International License.