Ricardo
Silva Parente
Institute
of Technology and Education Galileo of Amazon - ITEGAM, Brazil
E-mail: ricardosilvaparente@gmail.com
Italo Rodrigo
Soares Silva
Institute
of Technology and Education Galileo of Amazon - ITEGAM, Brazil
E-mail: italo.computation@gmail.com
Paulo Oliveira
Siqueira Junior
Institute of
Technology and Education Galileo of Amazon - ITEGAM, Brazil
E-mail: paulojunior051996@gmail.com
Iracyanne Retto
Uhlmann
Institute
of Technology and Education Galileo of Amazon - ITEGAM, Brazil
E-mail: iracyanne.uhlmann@gmail.com
Submission: 12/8/2020
Accept: 3/31/2021
ABSTRACT
It is
apparent the industrial processes transformations caused by industry 4.0 are in
advance in some countries like China, Japan, Germany and United States. But, in
return, the developing countries, as the emergent Brazil, seem like to have a
long way to achieve digital era. Considering manufacturing processes as the starting
point the rise of industry 4.0, this research aims to show a review about the
most important technologies used in smart manufacturing, including the main
challenges to implement it at Brazil. The papers were collected from Web of
Science (WoS), comprising 114 articles and 2 books to
underpin this study. This exploratory research resulted in the presentation of
some challenges faced by Brazilian industry to join the new industrial era,
such as poor technological infrastructure, besides lack of investment in
technologies and training of qualified people. Even though the primary
motivation of this research was to present a panorama of smart manufacturing
for Brazil, this study results contributes to the most of emergent countries,
bringing together general concepts and addressing practical applications
developed by several researchers from the international academic community.
Keywords: Smart manufacturing; Industry 4.0; Manufacturing Process; IoT.
1.
INTRODUCTION
Digitalization
of data is a reality today and has been growing more and more in the
technological age, due to its great importance for factories, in which this way
it is possible to exchange data and interoperability between the smart
equipment of a factory, thus allowing the implementation of the Smart
manufacturing approach (Santos et al., 2017; Liu et al., 2020; Sahal, Breslin & Ali, 2020).
Today's
factories constantly deal with large demand for goods with a high degree of
diversity, which makes it difficult to manufacture products in small batches
(Lu, Xu & Wang, 2020). In the midst of this great difficulty in serving
consumers with smaller and more personalized batches, manufacturers begin to
enter a new era, in which product customization, integration of machines in
virtual environments and the use of artificial intelligence (AI) becomes
necessary to obtain profits and maintain the company's competitiveness in the
market. Such an era is known as the fourth revolution, popularly called
industry 4.0 (Lu, Xu & Wang, 2020; Tortorella et al., 2018; Tang & Veelenturf, 2019; Da Silva & Almeida, 2020).
Industry
4.0 has been growing rapidly, despite difficulties in implementing it. Some of
the obstacles encountered are technological changes that lead to changes in
layout and design in industries (Müller, Buliga &
Voigt, 2020). In order for the fourth industrial revolution to be implemented,
it is essential to redesign the manufacturing process, so that smart
manufacturing production lines are inserted in the industry (Moktadir et al., 2018).
Some
techniques/methodologies can be considered as a fundamental part of the fourth
revolution paradigm when they are related to manufacturing (Yadav et al.,
2020). Techniques such as Internet of Things (IoT), Big Data, Blockchain and
Machine Learning are used to improve the manufacturing process in industry 4.0.
(Souza et al., 2020).
Data
virtualization has been increasing in recent years in the industry (Müller,
Jaeger & Hanewinkel, 2019), with this the IoT
gains strength, connecting an entire manufacturing process, making it fully
automated and exchanging information between machines (Kerin
& Pham, 2019; Shah & Wang, 2020). One of the benefits that IoT can
bring to the manufacturing process is the ability to produce varied products
with minimal or no workers operating the machines (Fox & Subic, 2019).
This
research aims to show a review about the most important technologies used in
smart manufacturing, including the main challenges to implement it at Brazil.
The research carried out has its relevance focused on the dissemination of
knowledge of the difficulties found in the Brazilian scenario in relation to
industry 4.0, analogous to the scenario of other emerging countries such as
India and South Africa that are in the initial stage of implementation (Menelau et al, 2019).
In
general, the research contributes to a relevant and notorious topic in the
academic community, considering the other publications of renowned authors who
carry out research and develop solutions applied to intelligent manufacturing.
According to the bibliographic review, it was found that industry 4.0 has
numerous challenges to be overcome, mainly in Brazil, such challenges can be
summed up in two major aspects, investment in technologies and training of
qualified people to work in this new era.
2.
CONTEXTUALIZATION OF MANUFACTURING
PROCESSES
Since
antiquity, human beings have learned to create tools, the act of creating is
what makes possible a process that determines a product (BI et al., 2017). Over
time came the need to evolve, and with that Industrial Revolution emerged,
which allowed the involvement of numerous experiments and case studies that
enabled researchers to new methods of optimization in manufacturing processes (Ćwiklicki et al., 2020; Takezawa
et al., 2020).
In the
literature, the concept of process is defined by the raw material that gives
rise to the finished product (Ozkan-Ozen et al.,
2020), a process is carried out according to the need for a product or tool,
the raw material is intrinsically important for to obtain manufacturing,
through well-organized goals and plans that enable the best productivity in a
company (Lin et al., 2020).
With the
implementation of continuous improvements (Xia et al., 2020; Moktadir et al., 2018) and the optimization of time waste
in lean manufacturing processes (Tortorella & Fettermann,
2018), the process classification was developed, which are related to the
functions due to the type of process, energy involved, working temperature and
working voltage (Kiss & Grievink, 2020).
The types
of processes such as mechanical forming, casting, welding, powder metallurgy,
machining and others, are specific in the creation of metallic materials (Mokhtar
& Nasooti, 2020). Those that are driven by
techniques and tools such as turning, milling, drilling, planning, abrasive
jet, EDM (Electrical Discharge Machining), laser, plasma, lamination,
extrusion, stamping and many others, for each type of technique a group is
formed that makes up the type of process (Nwankwo et al., 2020).
In addition,
there is a classification of the types of energy involved that deal with
mechanical, metallurgical and intermediary processes (Moon et al., 2020).
Another classification is given by the working temperature, with an analysis by
means of variables such as cold and hot, with this the phenomena that lead to
the production of the material for the finished product are considered (Buswell et al., 2020). Finally, the working stress
classifies the process through the deformation or removal of stress in materials
that lead to the shape of a product (Liu & Shi, 2020).
Smart
manufacturing has been evolving according to the need to optimize processes,
dependent on technologies that increase productivity and reduce costs, making
possible methods previously not practiced, allowing greater reach in the
analysis of investment, productivity and business performance (Kusiak, 2019).
Thus, the
implementation of industry 4.0 model brings high expectations regarding the
ease of information, through data processing, internet of things, data
analysis, information security and artificial intelligence (Mittal et al.,
2019; Moeuf et al., 2018), resulting in large
investments and greater complexity in the use of resources and training of
qualified people.
Due to the
inclusion of technologies that include a communication facility, there is
transparency between the processes, where it does not make explicit how the
digitization method is performed (Jones et al., 2020; Zhuang et al., 2020),
only allows the use and guarantees the integrity of the data through smart
techniques and ways of applying smart manufacturing in practice (Gupta et al.,
2020).
In this
way, factories become intelligent and embrace innovative resources with regard
to technology (Kusiak, 2019; Kusiak,
2018). The manufacturing process, which is an extremely important step towards
the finalization of the product, is seen as a great concentrator of
methodologies that minimize the gaps in time and process of a product (Walheer & He, 2020; Ghayour et al., 2020).
With the
advent of intelligent manufacturing, failure projections are minimized
considerably (Kusiak, 2019), this is done by methods
such as Deep Learning and Machine Learning (Tortorella et al., 2020; Romeo et
al., 2020), which are techniques of computational intelligence that approach
and simulate machine learning through trial and error, often through inferences
and others with predetermined meta-heuristics.
In
addition, there are also the pillars of the IoT, considering the best data
processing through a distributed architecture that offers security in
anonymity. The use of algorithms and techniques like Blockchain are notoriously
studied, applied and improved by scientists who develop more and more new
solutions, allowing scientific advancement of industry 4.0.
3.
PAPERS COLLECTION
For the development of this study, an exploratory search was carried out
on the Web of Science database through the Science Direct and Google Scholar
platform, in which the following keywords were used: “Industry 4.0”, “Smart
Manufacturing”, “Manufacturing processes”, “Blockchain”, “Robotic”, “Challenges
of Brazil in smart manufacturing”, “Smart manufacturing on process industry”,
“internet of things and its pillars”, “robotics in industry” and “intelligent
manufacturing processes”. 114 articles from 69 journals and 2 books from 2
publishers were used.
Figure
1 shows main research methods used by authors, showing that "Review"
is the method chosen for the most of papers (42), followed by "Case
Study" (38).
Figure 1:
Main research methods.
The
following lists all the techniques and technologies found in the cited
articles: Cylinder Detection, Artificial Neural Networks, Computed Tomography,
Cloud Computing, Big Data, Space Industry, Mathematics Paradigms, IoT,
Detection Network, Digital Fabrication, Linear Programming and Multi-Objective
Optimization, Embedded Systems, 3D Printing, Digitization, Delphi-Based
Scenario, Health Systems, Augmented Reality, Optimization, Cyber-Physical
Systems, Cloud Computing, Robotics, Technique Additive Manufacturing, Web
Framework, Robots, Delamination, Virtual Reality (VR), Digital Twin,
Blockchain, Process Systems Engineering (PSE), Data Mining, Automated
Manufacturing Systems, Digital Manufacturing, Artificial Intelligence, Graying,
Binarization Methods, Total Factor Productivity (TFP), Internet of robotic
things (IoRT), Deep Reinforcement Learning (DFL),
Imitation Learning (IL), Analytical and Optimization Tool, Automation and
Manufacturing Digital Thread, Descriptive Analysis, Technology Foresight,
Automation Construction Robotics, Bibliometric, Simulation,Decision
Support Tool, Best-Worst method (BWM) and Smart Technology, Method based on the
Integrated and Normalized Cross Power Spectral Density of the Background
Noises, Research, Digitization in Wood Supply, Triple Bottom Line, fuzzy,
TOPSIS Multi-Criteria Method, Deep Learning Techniques, GPU Virtualization and
Serverless Computing, Economic Analysis, Integrated Process Safety Management
System (IPSMS) Model, Fuzzy Analytic Network Process (ANP),
Analytics-Statistics Mixed Training (ASMT), Developed Technology Computer-Aided
Design (TCAD), Text Mining, Digital Twin, Radio-Frequency Identification
(RFID), Smart Sensors, Machine Learning (ML), Decision Tree, Bayesian Filter, Stream
Processing, Semi-Autonomous Programming, Optimization Algorithm and
Metaheuristic Algorithms, Cyber-Physical Human Systems (CPHSs), Real-time
Embedded Computing Systems, Interval type-2 Fuzzy Sets, NSGA-II, Sequential
Inherent Strain Method and Sensitivity Analysis, Drones, Framework-New IT
Driven Service-Oriented, Smart Manufacturing (SoSM),
Organizational Learning (OL), Multivariate Analysis and Lean Production (LP),
Data Envelopment Analysis, Computing Fog Based, Industrial Cloud Robotics
(ICR), Cloud Service, Robust Best Worst Method (RBWM), Autonomous Car and
Intelligent Robot, Structure Entropy Model and Structural Order Parameter .
4.
APPROACHES AND TECHNOLOGIES USED IN
SMART MANUFACTURING
Among the technologies that involve
manufacturing processes are additive manufacturing, virtual reality, augmented
reality and robots (Mittal et al., 2019; Moeuf et
al., 2018). Digital Twin was conceptually proposed for a future vision for
smart manufacturing, representing reality in a digital perspective (Tao et al.,
2018). Digital Twin is a production methodology that allows a reconfiguration
or simulation through decision making in manufacturing strategies (Grieves
& Vickers, 2017; Tao & Qi, 2017), one of the great benefits of this
technology is the mirroring of processes through computational models and
simulators, allowing real-time management (Qi & Tao, 2018).
In the study of Xia et al. (2020) and Zheng
and Sivabalan (2020), the methodology presented and
applied to minimize the gap between the physical and the digital is the Digital
Twin, allows the use of intelligent manufacturing.
Figure 2 illustrates the conceptual model of
the Digital Twin in a practical example of virtualization or digitizing data
and machinery for the virtual environment, thus generating its digital twin.
Figure 2:
Conceptual model of Digital Twin.
Source: Zheng
and Sivabalan (2020).
Another technology to be highlighted that is
being used a lot in the manufacturing process in the industries is the IoT, if
the Digital Twin takes the real to the virtual, the IoT connects the machines
and allows “conversation” between them. In the articles by Hang, Ullah and Kim
(2020) and Souza et al. (2020), IoT is used in conjunction with another
methodology, blockchain, allowing connectivity and data security in the
manufacturing process. The blockchain in the manufacturing process allows
product traceability in all logistics, thus keeping a block of important product
information (Pólvora et al., 2020).
With the connectivity and integration of IoT and Digital Twin, another
technology comes to further strengthen smart manufacturing, popularly known as
artificial intelligence (Azouz & Pierreval, 2019; Mana et al., 2018), which has N
optimization and prediction algorithms. In the case of the work by
Ruiz-Sarmiento et al. (2020), the prediction technique called Artificial Neural
Networks is used to assess the health of assets in a stainless-steel industry.
Another AI (Artificial Intelligence) technique used is Fuzzy Logic, the
article by Shukla et al. (2020) exemplifies the use of such a technique. With
the great growth of industry 4.0, industrial plants began to spend more energy
due to the connectivity provided by the IoT, and to alleviate energy
consumption by industrial plants, Shukla et al. (2020) applies fuzzy logic with
Genetic Algorithm (AG).
Figure 3 illustrates artificial intelligence
and its subareas, totaling 8 intelligent techniques that are used in the model
of integration of technologies in smart manufacturing, which allows
synchronization through real-time systems and data processing that generates
information useful for decision making.
Figure 3:
AI and subareas.
Source: Mao et
al., (2020).
To be applied IoT, Digital Twin, and AI it is
necessary to automate processes in factories, and industries must have robots
that play a fundamental role in various sectors, becoming indispensable for
intelligent manufacturing (Yan et al., 2017).
Over the years, strategies for improving
manufacturing processes have been developed and continue to evolve constantly,
seeking results of excellence and greater profitability for the industry (Parashar
et al., 2019; Fox & Subic, 2019; Craveiroa et
al., 2019), the concepts of the new industry model, smart manufacturing, arise,
that is, an intelligent industry that accommodates a cluster of techniques and
technologies that cooperate with each other through methodologies to carry out
the least effort and highest productivity in the industry (Wu et al., 2018).
With these operations, the idea of
cyber-physical systems arises, which are characterized by collaborative
control, in addition to other technical terms known as connectivity,
interoperability, real-time communication, among others, that make the
difference in working together with the information worked on (Sharpe et al.,
2019; Zheng & Sivabalan, 2020). This type of
sector is constantly challenged by the temporal structures of the machines,
with different times for each machine working in parallel or dynamically.
Due to the need to optimize technologies and
processes characterized in the industry, which is one of the sectors with a
high rate of profitability and productivity, research related to the theme is
triggered, generating numerous contributions in the academy and in the sectors
that work directly with automation in the manufacturing processes (Catalá et al., 2016; Moreira & Correa, 1998).
For Raj (2020), it was possible to identify
the needs to apply an intelligent model in the manufacturing processes,
considering the Brazilian scenario as model:
·
Enter into the dispute of the technological
productive sector allowing negotiations with other countries, besides
strengthening a professional relationship between qualified scientists;
·
Increase the employment rate and amplify the
course market focused on industry 4.0;
·
Moving working capital and allowing economic
development in the states;
·
Products with high added value when using high
performance equipment and higher manufacturing quality;
·
Increase in work efficiency with accurate and
qualified productivity with statistical content of analysis.
In accordance with the factors presented, the industry 4.0 model consists of equipment with high performance and
highly qualified professionals, the technologies and services that consolidate
the pillars of intelligent manufacturing, for Kusiak
(2018) are: manufacturing technologies and processes; materials; data
processing; predictive engineering; sustainability; sharing resources and
networks.
According to Kusiak
(2019), for the application of manufacturing processes, some technologies are
necessary, such as additive manufacturing, virtual reality, augmented reality
and robots, with these elements the basic structure for an intelligent
manufacturing process is obtained.
In the perspective of
industrial evolution, the smart industry model has been preparing for a stage
with great challenges and innovative principles (Lins
& Oliveira, 2020), with the concept of additive manufacturing and elements
such as 3D printing (Klockner et al., 2020; Benitez et al., 2020) will be
commonly used in several sectors acting mainly in the production stage,
allowing a greater reach in certain situations.
With mass production using
this technology, there will be a guarantee of an accurate precision in the
development of parts or finished products, through computational software it is
possible to determine the characteristics of the element such as: color,
dimension, thickness, depth, height, type of material, size and others that are
previously configured (Robinson et al., 2019; Maresch
& Gartner, 2020).
With this type of work that
can be on a large scale, processes such as machining are easily exchanged, or
even in civil construction where machines build houses using the 3D printer (Craveiroa et al., 2019).
For Den Boer et al. (2020),
in his research on “advantages and challenges in the spare parts supply chain”,
it is possible to identify some advantages of using this method that are listed
as follows:
Speed:
Manufacture in high definition and quality of a product or part, being able to
be distributed or supplied in several sectors, being a prosthesis used in
surgeries or even large-scale constructions with heavy materials and large
machines, in addition to enabling prototyping fast;
Cost:
Measurable control of the quantity of elements produced, without limitations
regarding hardware or machinery, expanding new forms of the market;
Design freedom and complexity:
With qualified and qualified professionals in the subject, you get the freedom
to customize a certain product at a low cost, in view of the customer's needs
and even the rate of evolution in production, obtaining greater results in the
supply and manufacture;
Customization:
Through the use of specialist or proprietary software created by a development
team, it allows the use of legal and personalized form in the creation of plans
and models of objects and elements of the project to be printed;
Sustainability:
Control the use of raw materials and high-cost materials, in addition to
avoiding energy costs and manufacturing waste.
For some authors like Dev et
al. (2020), Bauza et al. (2018) and Mittal et al.
(2019), the management of additive manufacturing using 3D printing is used in 3
stages, making it possible to carry out the planning, simulation and production
of the part or product:
3D Modeling:
Created in computer software such as AutoCAD;
Sizing in layers:
With the definition of some parameters, the slicing process will be performed,
in this way a file in g-code format is generated;
Production process:
The generated file is sent to the 3D printer which, after reading and
interpreting the code, will print using the coordinates established by the
producer, depending on the object to be printed, the manufacturing time can
vary from hours to days.
Thus, the expectation of
using 3D printing in various sectors of commerce and industry is high, directly
impacting the local economy, in addition to influencing the supply of raw
materials for the manufacture of finished products (Dev et al., 2020; Pacchini et al., 2019; Culot et
al., 2020).
Another important technology
to be highlighted is the virtual reality characterized by the generation of
environments simulated by computer, this tool becomes necessary mainly in the
presentation of objects or environments through interfaces rendered in high
definition allocated in hardware with transmission capacity, as is case of 3D
glasses (Roldán et al., 2019; Chiarello
et al., 2018). In addition to simulating the production environment through
this equipment, it also brings great benefits and facilitates communication,
increasing the focus on business (Masood & Sonntag, 2020).
Thus, in the near future it
will be possible to immerse the user in virtual reality, through sensors,
actuators and neuro-computational connections, which allow the use of the
senses, bringing in fact reality resulting in bodily phenomena such as pain,
anxiety, fear, anger, joy and others (Mittal et al., 2019).
Thus, it is worth emphasizing
expectations regarding the use of this innovative resource as an element of
work in industry 4.0, one of the applications is the realization of practical
training, reducing costs in team trips to seek knowledge and technical
qualification, another important point is the cheapness of the process, with
the use of virtual simulators, allowing greater security and increasing the
operational efficiency of training (Pejic-Bach et al., 2020; Kerin & Pham, 2019).
Cases in Brazil related to
the use of VR are presented in international magazines and Brazilian blogs, as
is the case of automakers in Minas Gerais where Fiat car models are simulated
several times by virtual simulators, avoiding errors in the manufacturing
process and increasing the degree of quality in details unnoticed through
predicted calculations, thanks to the simulation model.
According to Pallavicini et
al. (2016), some of the applications of virtual reality also involve areas such
as: workplace safety; training and capacity building; industrial maintenance;
maintenance of processes on the production line.
Through the factors presented
it is possible to identify a leap in production and manufacture of new
technologies with these resources, among which there is the game market that
evolves as new intelligent computational techniques are developed (Xia et al.,
2020; Zheng & Sivabalan, 2020).
Just as it was with the
concept of AI in virtual stores, embedded systems, autonomous systems of
supervision, prediction and data collection, in addition to technologies that
virtualize environments for people with visual impairments, attitudes like
these bring the real essence of science in creating technology which benefits
not only in the manufacturing processes in an industry, but also in the best
condition for an employee to carry out operating tasks within the manufacturing
environment (Santos et al., 2017; Kerin & Pham,
2019).
The industry will also be
able to invest in technologies that support augmented reality (Müller, Jaeger
& Hanewinkel, 2019), with a higher expectation in
relation to the other, having the user's vision in a real environment as a
major characteristic, an example would be the projection of a person in another
distant location through a hologram, or even a technical visit to a distant
company through virtualization in the environment, the possibilities are
diverse (Fox et al., 2020).
Using computing, numerous
technological solutions are possible, through the analysis of variables and the
development of mathematical models, augmented reality has great expectations
and benefits in several sectors of the industry (D'anniballe
et al., 2020; Tao et al., 2019).
According to Van Lopik et al. (2020), this technology becomes versatile and
allows a range of applications in view of the industrial scenario, such as:
· Training,
with activities carried out by means of intelligent simulators, achieving
greater productivity and control of the processes;
· Visualization
of the exact locations in which several items must be arranged, allowing better
conditions for performing tasks in the operator's process;
· Recognition
of parts and patterns;
· Overlay
images of the internal hardware of industrial machines to assist technicians'
work, allowing fault identification and parts exchange with ease.
· Among
the most diverse uses of augmented reality in Brazil there are:
· Development
of applications and software that scan machine data and illustrate or describe
through interfaces the stages of maintenance of the same by a technician while
performing it;
· Accident
prevention, where employees are able to walk with their cell phones around the
factory while interacting with the protective equipment required in each
sector, with this method the training experience has become better, in addition
to avoiding expenses with the construction of specific safety rooms in the
factory;
· Quality
Inspection with the use of glasses with augmented reality technology like Glass
from Google, assisting in the inspection of tractor assembly.
As mentioned by Lovreglio and Kinateder (2020),
and Wedel et al. (2020), research is carried out in several countries, with
exploratory research, action research and even qualitative and quantitative ones,
analyzing and identifying ways of improving technologies such as augmented
reality, through computational intelligence that it is possible to expand
horizons in models of industrialization in manufacturing processes.
According to research by Porpiglia et al. (2020), with Artificial Neural Networks
(ANN) or even Genetic Algorithms (AG), formation improvements in image frames
and virtualization in real environments are possible, the construction of
pixels may change according to the mathematical model used (Naranjo et al.,
2020), this allows an optical variant of the user, such as people with low
degree of vision, or even considering the level of brightness of the
environment (Li et al., 2020).
Some computer scientists
constantly develop research related to optimized search algorithms (Shabani et al., 2020), that are applied in cases like this
that present problems of rendering images with binary blocks of pixels (Fernando
et al., 2020; Bu et al., 2020), several models are developed as research to
improve the optimization of image rendering, which depends on the need for use.
The greatest technological
invention after the first computer is in fact in the area of automation with
the emergence of the robot (Syed et al., 2020; Pekkarinen
et al., 2020), it allows and if it has great futuristic expectations, several
films are produced about the theme that they discuss about the future of
humanity with robotic interaction, in the industry it is not different and the
applications with the use of robotic arms and complete robots are diverse (Franklin
et al., 2020; Lee et al., 2020).
One of the examples to be
cited is the robotic arm used in a production line, capable of making decisions
and identifying parts using variables such as size, thickness, depth, color and
type of material (Yun et al., 2016; Xu et al., 2020). With the evolution of
technologies and research on the subject, new models of robots were built,
among them the robot builder that is already a reality in German industry and
in other countries (Melenbrink et al., 2020; WANG et
al., 2020).
With 3D printing it is
possible to develop customized robots, with the material specified in
specialist software and the trained professional to develop the robot's
construction plan (Petrick & Simpson, 2013),
another important point to be highlighted is about the research addressed by
Xia et al. (2020), he explains about the processes of using the digital twin to
train a deep reinforcement learning agent for factories in a factory
environment with interfaces and computational intelligence.
In his research, it is
reported the way of programming robots using the Digital Twin, through control
modules where a sequence of commands is digitized and executed through
programmed actions to only then start the simulation process. This procedure in
a developer's view can be determined as an input of unit events that resemble
PLC programs, having the input and output signals controlled by an intelligent
and autonomous signal system, with a high level of programming, its application
may vary from small and medium-sized companies (Xia et al., 2020).
Another application of
robotics is the construction of Drones (Hang, Ullah & Kim, 2020), with a
high level of performance in relation to the autonomous systems used in mobile
vehicle networks, besides including specific hardware to perform certain tasks,
it also has algorithms such as learning machine learning and deep learning that
are widely used in heuristic decision-making methods. The inferences of data are
through a specific technical infrastructure acting with the sending of data to
the cloud and a client module capable of interpreting and processing the data,
thereby generating useful information for the administrators and managers of
sectors that work with these technologies. (Yan et al., 2017).
5.
CASES AND PRACTICAL APPLICATIONS
Intelligent manufacturing can
be applied in various sectors and applications, such as Steelmaking industry;
Energy efficiency; Factories in general; Training of workers; Civil Construction
and Automation of processes intelligently using robots.
The stainless steel industry,
as stated in the article by Ruiz-Sarmiento et al., (2020), the authors discuss
the machines used in the manufacture of steel sheets with a high level of quality,
in which they propose a way to minimize the damage to these machines through
prediction, made by Machine Learning which is a branch of AI.
Industry 4.0 values the
integration of all machinery so that the application of IoT and AI is possible,
however, the integration of all machines means that industrial plants consume
more electricity in each plant, to solve the difficulty it is necessary to find
the shortest time and the lowest energy consumption to perform a task (Shukla et
al., 2020). Having the problem, the authors Shukla et al., (2020), applied
multi-objective AG and fuzzy logic to have a balance between the time to be
fulfilled in the manufacture and the amount of electrical energy, achieving an
optimal result. It is noted that, to achieve the digital technology present in
industry 4.0, AI must be heavily worked on.
In addition to AI techniques,
another methodology that has many applications is Digital Twin, which can be
applied not only in the manufacturing process, but also in the supply process.
According to Lu et al. (2020), Digital Twin can be applied in factories in
general, creating a virtual model of the real model, so there can be
simulations with real data in an external environment to the production, which
can bring benefits such as optimization of manufacturing processes,
identification of problems in the production line, among others.
A practical application of Virtual Reality that brings
many benefits is the training of people for manufacturing processes that
involve manufacturing and assembling products (Roldán
et al, 2019), as is the case with IC.IDO which is a tool to display processes
of machining through a computer-aided logical interface and virtual reality (Giannuzzi, Papadia & Pascarelli, 2020) or even in cases where VR is used in
highly dangerous projects as shown in the research of nuclear devices, where it
is used in all phases of the project, including investigating plasma geometry,
stability, the scraping layer and the discharge process and conducting an
engineering analysis of its electromagnetic, thermodynamic and structural
characteristics. (Wang & Chen, 2020).
In civil construction there
are examples of intelligent construction, in which additive manufacturing is
used. In the article by Craveiroa et al. (2019), it
is demonstrated how civil construction makes use of this resource of industry
4.0, which in the specific case is Construction 4.0, the article shows that
construction is taking an important step in evolution, building houses,
buildings and monuments fully automated and with 3D printers, accelerating the
construction process.
Amid so many technologies and
methodologies used in smart manufacturing in this fourth Industrial Revolution,
one of which stands out is intelligent automation through connectivity and exchange
of information in real time (Yan et al., 2017). One of the uses of this process
is the interaction of data in the cloud as is the case of the approach based on
a robust linear time circle detection algorithm that discards outliers,
allowing the manipulation of data sets with different levels of density and
noise while uses a variable and relative inferences model, and with this
projecting the data in the cloud, this technique was compared with
state-of-the-art methods and it was found to be superior in terms of precision
and robustness that directly impact noise while maintaining an execution time
competitive. (Araújo & Oliveira, 2020).
Table 1 shows the scenario of some advances regarding
the implementation that confirms the industrialization 4.0 model in Brazil.
Table 1: Industrial technological advances.
Company |
Description |
Romi |
Launch of a machining machine capable of
molding metal parts by removing or adding layers, being able to register and
receive data on processes, an element similar to additive manufacturing with
IoT. |
Birmind Automação |
It works with preventive inspection and
monitoring software, providing factory equipment cost data, pointing out any
flaws that may have an impact on the company's productivity. |
Automatsmart Tech |
It works with an industrial maintenance data
management platform, based on computational intelligence working with
preventive analysis and data storage in IoT cloud. |
Autaza |
It works with an industrial inspection system
using Computer Vision, with the capture of images by cameras on the
production line, the system evaluates the quality of the product produced by
means of computational intelligence. |
Source: Adapted from Nazaré et al. (2018).
6.
STATE OF DIGITAL MANUFACTURING AT
BRAZIL AND OPPORTUNITIES
The Brazilian industry
scenario advances slowly with small contributions related to the theme, a fact
that is mainly explained by the regional economy, although several studies are
being carried out that directly imply the consolidation of this industrial revolution.
In their research, Nara et
al. (2020), addresses the impact of industry 4.0 technologies on
sustainability, based on economic factors, using the Triple Bottom Line
perspective for sustainability. As a result, it was shown that the Internet of
things, cyber-physical systems, sensors and the Big data implementation is a
determining factor for sustainable development. In addition, the authors
highlight the negative impacts of robots on job creation and the low influence
of cloud computing and the integration technology system for sustainable
development.
Thus, edge technologies in
the context of smart manufacturing show the importance of synchronism and
interoperability between the other components that make up the industry (Ren et
al., 2019). Bringing to the context of the manufacturing process, there is a
decrease in the gaps that are modeled and analyzed in each case of industry,
considering variables such as production time, maximum production capacity, in
addition to others that may or may not impact the final manufacturing
performance.
According to the literature review carried out by
Teixeira et al. (2019), where the paths of industry 4.0 in Brazil in the steel
sector are investigated, the results indicate that there is a need to update
the industry, as well as the teaching centers to prepare the future manager and
engineer for new technologies and integration in the industrial processes, with
many challenges related to the change in mentality that directly impact the
socioeconomic scope. It is more than a matter of moving forward, it is about
being prepared or not or preparing for the necessary changes (Evans, 2018).
In Brazil, the application of
increasingly complex intelligent technologies (technological clusters) impacts transformations
in industrial lines, as well as in organizational structures, in addition to
better security, however there is a need for high qualification of manpower for
the technologies brought by industry 4.0 (Teixeira et al., 2019). For Rampasso et. al. (2020) one of the major difficulties in
implementing industry 4.0 in the brazilian scenario
is related to a strengthening in the training of professionals, with this
through a systematic review of the literature it was possible to verify that
out of 10 competencies analyzed in a database, only 6 were identified as a
research target, leaving aside: people management, service orientation,
negotiation and cognitive flexibility.
According to Souza and Vieira (2020)
the great challenge of implementing industry 4.0 is strongly focused on the
creation of public policies for science and technology and investment in
professional education, for Brazil to consider itself one of the countries that
make industry 4.0 a the flagship of the development
process will need to prioritize public policies for industrial and
technological development, reaching models of strategy in the state with an
important role in the realization and articulation of programs with other
actors and agents (Souza & Vieira, 2020).
The country invests approximately
1.27% of its GDP (Gross Domestic Product) in R&D (Research and Development)
with public and business spending, which makes it much less than the average of
OECD (Organization for Economic Cooperation and Development) countries, where
investment represents 2.38% of GDP, however, it is above countries Latin
American countries, such as Mexico and Argentina, and even countries such as
Spain or Portugal (Negri, 2018, p. 23). With these data it is possible to
understand that investment in professional education is important and it
becomes a strong ally to the creation of public policies in the scope of
science and technology making this a structuring factor for the country.
In addition Nazaré et al. (2018)
states that the difficulties and challenges are not limited only to these
factors, but also due to the lack of investments in technologies and equipment
prepared for the specific tasks that allow the integration of industry 4.0
model, change and alteration in layouts, modification in production chain, in
addition to the high investment in tools and intelligent systems that allow the
processing of data and the transformation of this into decision information
autonomously.
Soon, the industry will have
a greater expectation in the service segment, molding professionals able to act
in the context of the smart industry, more and more technical knowledge will be
required to manage the other processes of the company or industry, from the
acquisition of raw material to finish goods, be it a service or even a
measurable product.
For Bogle (2017), some
challenges should be highlighted regarding the implementation of technologies
in the scenario of manufacturing processes, considering professionals in the
area of Process Engineering, among them is highlighted: flexibility and
uncertainty; responsiveness and agility; robustness and security; prediction of
properties and functions of the mixture; new paradigms of modeling and
mathematics.
This model aims to link
disruptive technologies to manufacturing systems, combining intelligent
operations and supply chain management (Zhang & David, 2020), some
challenges are shown in Table 2 for the implementation of intelligent
manufacturing in some industry segments in Brazil.
Table 2: Challenges for the implementation of industry
4.0 in Brazil.
Authors |
Challenges of for industry
4.0 in Brazil |
Brito (2017) |
There is no high competitiveness among companies for the adoption of
industry 4.0 in the manufacturing process, besides the small amount of products with a high rate of innovation. |
Da Silva, Vasconcelos and Campos (2019) |
In the Brazilian territory, the implementation of industry 4.0 suffers
with some difficulties, among them the question of technology developed in
the country that is not of the first world. |
Teixeira et al. (2019) |
Some of the challenges encountered by Brazilian industry in the
transition to the fourth industrial revolution are the new paradigms, the
socioeconomic impacts and the change in mentality that must exist. |
Vello and Volante (2019) |
One of the most impacting factors in the challenges regarding the
implementation of the fourth industrial revolution in Brazil is the lack of
qualified labor, lack of technological infrastructure that can meet all the
integration that the new era needs and a factor that should be mentioned
which is the lack of government support. |
De Moura Souza and De Castro Vieira (2020) |
The difficulties of having the full potential of industry 4.0 on
Brazilian soil is directed at qualifying labor for Smart Manufacturing. |
According to the study by De
Moura Souza and De Castro Vieira (2020) and Storolli,
Makiya and Cesar (2019), in the new industrial era,
countries such as Germany, Japan, the United States and China are investing
heavily in the digitization and integration of industrial processes, so
countries that do not have the same momentum in the virtualization and
connectivity of the machines, it will have difficulty following the global
market, and Brazil is one of them.
Based on the article by Brito
(2017), Brazil has great challenges to overcome in order to implement industry
4.0, mainly in the manufacturing process. Based on this statement, the country
needs to reformulate public policies related to industry and trade that enable
business models and the exchange of knowledge with suppliers of accessible
technologies in the market.
According to Gonçalves
(2018), one of the ways to improve and implement smart manufacturing in Brazil
is through logical systems of partnerships that allow a solid relationship
between supplier and company, in addition to contributing with technological
resources, investment in qualified professionals who are prepared for the
adversities in a factory environment, with a high productivity rate and thus
allowing the incorporation or development of new technologies supported by the
industry 4.0 model.
Analyzing all the work, a
research opportunity to be explored is the study of mechanisms that can
minimize the difficulties that Brazil has in the implementation of industry
4.0, without involving the government, since all the obstacles that result in
the country's non-development are linked to government investments and the
qualification of professionals to work in this new industrial age.
The problem of professional
qualification can be solved through training using VR, as previously mentioned,
as it is a consolidated technology in the Brazilian market. A possible
resolution would be the adequacy of the large multinational industries in the
fourth revolution, this would generate a disparity in relation to competitors,
then, they would have to adapt to industry 4.0 to remain competitive in the
labor market, not only national, but also global.
7.
CONCLUSIONS
The present research had as main objective to present
the main digital technologies in the manufacturing process, considering the
Brazilian scenario that presents a slow advance in relation to developed
countries, in addition to listing some of its challenges, which was achieved
through a literature review that includes 114 articles classified as having a
high impact factor from the Web of Science (WoS)
database and 2 books.
In general, the research contributes
to the academic community, considering the other publications of renowned
authors who carry out research and develop solutions applied to intelligent
manufacturing. According to this review, it was found that industry 4.0 has
numerous challenges to be overcome, especially in Brazil, such challenges can
be summed up in two major strands, investment in technologies and training of
qualified people to work in this new era.
Among the difficulties pointed out
for the implementation of the intelligent model of industry in Brazil, is the
precarious technological infrastructure, which is responsible for supporting
the execution and accommodating integrated resources that make the
manufacturing processes viable, for example the speed of the internet is a
great influence o work of the pillars of industry 4.0, in view of the
synchronism of the information that will be necessary to generate indicators
and reports that assist in decision making and promote new forms of process
optimization.
Another important factor to be
highlighted is the formulation of public science and technology policies for
greater investment in the educational base, allowing the development of
qualified professionals and expanding the scope of new research in the
industry, which makes new models of strategy and articulation of feasible.
programs with other actors and agents.
This research was successful in
explaining the panorama of intelligent manufacturing in Brazil, where it was
possible to highlight contributions to most emerging countries with the
enrichment of the theme, especially in relation to Brazil, gathering general
concepts, weaknesses found in Brazil and addressing practical applications
developed by several researchers from the international academic community. In
addition to providing readers with easy-to-understand content with technical
details on the main technologies used in Smart Manufacturing, a systematic
literature review is suggested, comprising a larger database to encourage the
strengthening of the theme and adherence to the smart model of
industrialization by countries emerging.
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