Industry 4.0 In Manufacturing

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Industry 4.0

Interconnected and intelligent manufacturing is making a strong foothold, making competition challenging if industries don’t adopt manufacturing 4.0.

Manufacturing 4.0, also known as Industry 4.0, refers to the fourth industrial revolution, which is characterized by the integration of advanced technologies, such as the Internet of Things (IoT), artificial intelligence (AI), and machine learning, into the manufacturing process.

Equipment is getting smarter which is pushing manufacturers to manage the rapidly increasing complexity of hardware, software, and electronics integration within their products – a must to drive development and performance and create differentiation. It also helps plan, produces, and service products as required to meet the market dynamics across the sectors.

A Smart Factory is an Industrial Internet of Things- IIoT driven concept, that envisages a manufacturing as fully automatized and intelligent network of systems. This helps the manufacturing plant's facilities, machines, and logistics chains to operate without human intervention.

Moreover, a smart factory operates due to the exchange of data between production tools and machines and between all elements in the production technology chain. This leads to manufacturing effectiveness.

Lean manufacturing is a production philosophy that emphasizes the elimination of waste and the continuous improvement of efficiency. By focusing on value-added activities and minimizing non-value-added activities, lean manufacturing helps manufacturers to create more efficient and streamlined production processes.

Lean Manufacturing builds the foundation for effectively implementing Manufacturing 4.0.

To integrate Lean Manufacturing principles into Manufacturing 4.0, we need to focus on the following key areas

  • Data-driven decision-making: Industry 4.0 technologies enable manufacturers to collect and analyze data in real-time, optimizing production processes and identifying opportunities for improvement. Integrating lean principles, such as value stream mapping, Lean principles emphasize the use of efficient equipment and processes to eliminate waste. In a manufacturing 4.0 environment, this can be achieved through the use of advanced automation technologies, such as robotics, to streamline the production process.
  • Automation and technology: Lean principles emphasize the use of efficient equipment and processes to eliminate waste. In a manufacturing 4.0 environment, this can be achieved through the use of advanced automation technologies, such as robotics, to streamline the production process.
  • Continuous improvement: Lean manufacturing emphasizes the importance of continuous improvement, which can be achieved through data analytics and machine learning in a manufacturing 4.0 environment. By continuously analyzing data and making adjustments to the production process, it is possible to identify and eliminate waste, on a continual basis, leading to increased efficiency and productivity.

The impact of the smart factory on enterprises?

Factory 4.0 and Smart Manufacturing bring about huge benefits through efficiencies.

A dynamic production environment adapting both automation and intelligence improves reliability, effectiveness, and safety while reducing operation and downtime costs. This implies it makes the smart manufacturing lot leaner – MUDA-free. Lean manufacturing builds the foundation for Smart Factories & Smart Manufacturing.

10 Steps for making a Smart Factory through Lean Manufacturing:

The following steps should be taken to set up a smart manufacturing facility:

  • Define Business Goals
  • Map the Process Flow
  • Get trained in Lean Manufacturing
  • Map the Value Streams
  • Identify the wastes
  • Monitor, Audit, and Sustain the efficiency in each Value Stream
  • Calculate the Takt time required
  • Understand the Industrial Internet of things
  • Design the Smart Factory
  • Train team for Smart Manufacturing


At ADDVALUE Consulting Inc., we have a team of experts who are well-versed in both lean Manufacturing principles and manufacturing 4.0 technologies. By integrating these two approaches, we are able to help our clients achieve significant improvements in the efficiency and effectiveness of their manufacturing processes.

For more details about Lean Manufacturing Training & Consulting Email : info@avci-lean.com or Call / Whatsapp : +91 9824009792

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