Thursday, July 17, 2025

System Engineering - Systems Engineering - Bibliography

 


Very good content.

SEH 2.0 Fundamentals of Systems Engineering

Encyclopedia

Updated Feb 6, 2019

https://www.nasa.gov/reference/2-0-fundamentals-of-systems-engineering/


https://catalog.hathitrust.org/Record/002012487

System engineering; an introduction to the design of large-scale systems

[by] Harry H. Goode [and] Robert E. Machol.

Published: New York, McGraw-Hill, 1957.

Physical Description: 551 p. illus. 24 cm.

Full view available


Financial engineering;


Main Author: Goldman, Otto Berger.

Language(s): English

Published: New York, J. Wiley & sons, inc.; [etc., etc.] 1923.

Edition: 2d ed.

Subjects: Engineering

Physical Description: x, 325 p. incl. tables, diagrs. 23 cm.

https://catalog.hathitrust.org/Record/001511865


Industrial Engineering search results - interesting

http://onlinebooks.library.upenn.edu/webbin/book/browse?type=lcsubc&key=Industrial%20engineering&c=x

Previous Title: Industrial engineering

Language(s): English

Published: New York.

Note: v. 3-6: Engineering digest.

v. 1-2 have title: Technical literature.

https://catalog.hathitrust.org/Record/008616632




https://babel.hathitrust.org/cgi/pt?id=nyp.33433069057721&view=1up&seq=96    The page is titled industrial engineering


Gilbreth

1907

https://babel.hathitrust.org/cgi/pt?id=nyp.33433069057721&view=1up&seq=188&q1=gilbreth

https://babel.hathitrust.org/cgi/pt?id=nyp.33433069057721&view=1up&seq=339&q1=gilbreth

https://babel.hathitrust.org/cgi/pt?id=nyp.33433069057721&view=1up&seq=361&q1=gilbreth


Ud. 17.7.2025

Pub. 23.6.2021


Production Process Management - Manufacturing Process Management

 


https://blog.mesa.org/2016/08/why-and-how-to-use-production-process.html


https://en.wikipedia.org/wiki/Manufacturing_process_management




https://www.sciencedirect.com/science/article/abs/pii/096706619500026Q


https://www.ptc.com/en/technologies/plm/manufacturing-process-management


https://www.ibaset.com/solutions/manufacturing-execution-system/manufacturing-process-management/


https://www.iml.fraunhofer.de/en/fields_of_activity/enterprise-logistics/productionlogistics/prozessmanagement_und_ressourcenmanagement.html




Industrial Engineering - Some Important Concepts - A Presentation

 1.

Industrial Engineering - Simple Definition


IE is System Efficiency Engineering


Enterprise - System- Process - Operation - Element


IISE Definition


Interesting.


Systems Engineering Efficiency.

Falko Firl, 

Head of Fighter Radar Engineering at HENSOLDT,

https://www.linkedin.com/pulse/systems-engineering-efficiency-falko-firl/

-----------

2.

Industrial Engineering

Productivity (and other results areas) Engineering Related to Design and Redesign of Products, Systems, Facilities, and Processes.

-------------------

3.

Industrial Engineering

Significant value to be added through cost reduction based  on Productivity Improvement (Time reduction - machine time - man time)

Cost reduction can lead to lower prices, revenue growth and profit increase.

There can be direct increase in profit due to cost reduction.

IE sustains and grows business.

What is the value your are adding as a department?


Value Creation for the Organization by Industrial Engineers - Productivity Engineering Potential.

Propose and get approvals for Productivity Projects. Implement them and realize the RoI.

Lesson 13. Industrial Engineering FREE ONLINE Course #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2020/03/value-creation-model-for-industrial.html


--------------

4. 

Product Industrial Engineering

Value Analysis and Engineering

DFMA


Productivity Engineering I - Product Industrial Engineering.

Lesson 9. Industrial Engineering FREE ONLINE Course #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2012/09/product-design-industrial-engineering.html


------------------

5.

Facilities Industrial Engineering

Machine Study - Machine selection - Need for modification - Maintenance Policies - Replacement

Accessories Study - Tools Study

Work station layout

Plant Layout

------------

6. System Industrial Engineering

A system is used by many processes


Stores system

Materials purchase system

Production Planning System

-----------

7. Process Industrial Engineering

A process has operations.

1. Eliminate Operations

2. Examine dividing or combining operations

3. Change the sequence of operations

4. Simplify operations


Productivity Engineering II. Process Industrial Engineering. 

Lesson 10. Industrial Engineering FREE ONLINE Course #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2017/02/process-industrial-engineering.html


------------------

8. Simplify Operation Through Operation Analysis

Operation Analysis Sheet

Operation Data Sheet

Machine Effort Study - Machine study - Machine work or operation study

Human Effort Study - Study of Humans - Anatomy - physiology - Human work study - Motion study - Ergonomics

Industry - meaning - effort


Machine Work Study.

Taylor's Industrial Engineering - Machine Work Study. The first focus of industrial engineering.

Productivity Improvement of Machines in Machine Shop.

Lesson 17 . Industrial Engineering ONLINE Course  #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2020/05/productivity-improvement-in-machine.html


Taylor's Industrial Engineering - Human Work Study - Productivity Improvement and Development of Science in Mechanic Arts - F.W. Taylor. 
Lesson 18 . Industrial Engineering ONLINE Course  #IndustrialEngineering #Productivity #CostReduction
https://nraoiekc.blogspot.com/2013/08/development-of-science-in-mechanic-arts.html


Gilbreth's Human Effort Industrial Engineering - Productivity Science of Human Motions (Motion Study) - Part 1  
Lesson 21.  Industrial Engineering ONLINE Course #IndustrialEngineering #Productivity #CostReduction #HumanEffort #Operator #Mechanic
https://nraoiekc.blogspot.com/2015/08/motion-study-frank-b-gilbreth-part-1.html

-----------------

9.Productivity Science

Science based Productivity Engineering and Productivity Engineering.


Productivity Science  Principle of Industrial Engineering. Develop a science for each element of a man - machine system's work related to efficiency and productivity.

Lesson 8. Industrial Engineering FREE ONLINE Course #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2017/06/productivity-science-principle-of.html


Taylor - Productivity Science and Art of Metal Cutting - Important Points  #IndustrialEngineering #Productivity #CostReduction

Lesson 14. Industrial Engineering ONLINE Course 

https://nraoiekc.blogspot.com/2019/06/taylor-art-of-metal-cutting-important.html


Productivity Science Module - Lessons.

https://nraoiekc.blogspot.com/2021/05/productivity-science-module-lessons.html




-----------------

10. Productivity Engineering

Engineering to utilize benefits indicated by Productivity Science

----------------

11. Productivity Management - Management of IE Department and its activities

Planning IE studies.

Managing IE studies.

Planning IE Projects

Implementing IE Projects

Behavior Management - Self, Associates, Suppliers, Customers


Harrington Emerson - A Pioneer Industrial Engineer -  12 Principles of Efficiency - Principles of Productivity Management.

Lesson 29 - Industrial Engineering ONLINE Course #IndustrialEngineering #Productivity #CostReduction #Planning

https://nraoiekc.blogspot.com/2012/02/harrington-emerson-pioneer-industrial.html




----------------


12. Toyota Style Industrial Engineering - IE in Toyota Motors and Japan

Ohno - Mentions only Industrial Engineering in his books.

TPS is output of application of IE.

TPS description only outlines what is special in TPS. TPS used full IE principles and practices.

Managementt drives IE in Toyota. IE connected to Management.


--------------


13. Lean Manufacturing - Lean Thinking - Concept

Lean Mfg.  - Mfg. system with less inventory (compared to bulk manufacturing in batches).

Further extended - Lean Mfg. -With less resources (No muda - No excess resources)

Lean Thinking - Value - Value stream - Flow - Pull - Perfection.

                       Product - Process  - Facilities - Quantity Planning - Improvement


---------------


14. Productivity Planning - Productivity Budgeting

Planning for Productivity Improvement by Technique/Technology (Say based on IoT)

Planning for Productivity Improvement by Period (Next year planning)

--------------

15. Hoshin Kanri - Deployment of Productivity Planning


Now the world admires Japanese practice


---------------


16. Knowledge Management for IE

IE is a knowledge intensive task.

For each process, Industrial engineers have to collect lot of information on external developments apart from internal data.

Information on new technologies, new products, machines, devices - new offerings from subcontractors, consultants


-------------


17. Work Allocation in IE Departments.


Identification of processes in the organization.

Allocation of processes in the organization.

Identification of products  in the organization.

Allocation of products  in the organization.

Identification of facilities  in the organization.

Allocation of facilities  in the organization.

Identification of systems   in the organization.

Allocation of systems   in the organization.


-------------


18. Applied Industrial Engineering - Industrial Engineering Applications .


I strongly feel that industrial engineering applications have to progress parallel to progress in each branch in basic engineering. Every invention that is commercialised requires applied industrial engineering of the product and process on a continuous basis throughout its life cycle. These IE applications gives rise to improved engineering elements some of which can be even patented. 

I am trying to develop course materials that describe and give examples of this IE practice.

Industrial Engineering FREE ONLINE Course. 

https://nraoiekc.blogspot.com/2020/05/industrial-engineering-online-course.html


19. New Wave of Technology - Smart Manufacturing - Industrial Engineering 4.0 - Industrial Engineering 5,0



20.

I. Define Vision, Mission, and Scope

II. Strategic Alignment

III. Product, Process, Facility and System Improvement and Optimization. - IE  Methodologies

IV. Applied Industrial Engineering - New Technology Integration

V. Talent Development and Culture

VI. Performance Measurement and Reporting

VII. Collaboration and Communication

VIII. Continuous Improvement of the IE Department Itself



ud. 17.7.2025

Pub. 5.7.2025

Bosch Automotive - Bursa - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

Industrial Engineering 4.0 - Computer Aided Industrial Engineering: Work Systems Analysis in Industry 4.0

Rao, Kambhampati Venkata Satya Surya Narayana; Rathod, Aniket.  IIE Annual Conference. Proceedings; Norcross (2021): 49-54.

https://www.proquest.com/openview/d32ef32bbaa911d170e046479790c035/1  


10900+ Downloads/Reads so far. 
INTRODUCTION TO MODERN INDUSTRIAL ENGINEERING. 
Free Download EBook (122 pages).  Download from:

https://academia.edu/103626052/INTRODUCTION_TO_MODERN_INDUSTRIAL_ENGINEERING_Version_3_0 


Bosch Press Releases

https://www.bosch-presse.de/pressportal/de/en/


India

https://www.bosch-presse.de/pressportal/in/en/news/industry-4.0/smart-home/smart-home/

Bosch Automotive - Bursa

To secure future investments and resources for production of new products such as hydrogen components, Bosch Powertrain Solutions Plant in Bursa needed to further strengthen its cost leadership. By deploying AI use cases such as close loop process control for hydro-erosion, and upskilling 100% of the workforce, they reduced unit manufacturing cost by 9% and improved OEE by 9%.

TÜRKIYE | AUTOMOTIVE

Bosch Automotive - Bursa

BOSCH A.S. (TURKIYE)

Main Activities: Motor Vehicle Parts Manufacturing

Full name: Bosch Sanayi Ve Ticaret Anonim Sirketi

Profile Updated: March 28, 2024

https://www.emis.com/php/company-profile/TR/Bosch_AS_en_3358650.html

Bosch - Collaborating for sustainable logistics

Challenge

12 December 2023

The Bosch Bursa plant in Türkiye manufactures injectors for powertrain combustion engines destined mainly for the European market. The manufacturing site aims to reduce CO2 emissions by at least 15% by 2025 for Scope 1 and 2 and logistics.


To address its packaging and transportation emissions, the plant needed to build collaborations with its most important partners: suppliers, customers and logistics service providers (LSPs).



Turkish location of Bosch Manufacturing Solutions

https://www.youtube.com/watch?v=recVJpYLzUs


Ten years of Industry 4.0 in Bosch Since 2011 - Year by Year History

https://www.bosch.com/stories/10-years-industry-4-0-at-bosch/


June  2014

Bosch to extend  Bursa Plant in Turkey


The Bosch Group will be investing  Euro 300 million in the extension of its existing location in Bursa, 90 kilometers south of Istanbul. High-pressure injectors for diesel passenger cars will be manufactured in the new production hall, primarily for European automakers. The new 6,000-square meter hall will house production of the CRI2-20 diesel injector, which can inject fuel at pressures of up to 2,000 bar. 


Bosch already supplies injectors manufactured in Bursa for a quarter of all diesel cars produced in Europe. In addition, products such as gasoline injection systems and components for drive and control technology are manufactured at the Bursa location. 

The location has already been recognised numerous times for its outstanding quality. Among other things, it has already received the European Foundation for Quality Management’s (EFQM) prestigious “Best Company in Europe” award twice.





Apple Inc. - Industrial Engineering Activities - Industrial Engineering 4.0



CEAT - Halol, India Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant.

A to Z 2024 Blogging - Detailed Posts on  McKinsey - WEF Lighthouse Smart Manufacturing Industry 4.0 Plants -  Industrial Engineering 4.0   #IndustrialEngineering #Productivity #CostReduction

https://nraoiekc.blogspot.com/2024/03/a-to-z-2024-blogging-theme-mckinsey-wef.html

List of Industry 4.0 Light Houses - WEF - McKinsey - Have You Benchmarked with the Best in Industry 4.0 Implementation?

https://nraoiekc.blogspot.com/2024/01/list-of-industry-40-light-houses-wef.html


-----------------------


Bosch industry 4.0 use cases



Industry 4.0: 10 use cases for software in connected manufacturing

https://blog.bosch-digital.com/industry-4-0-10-use-cases-for-software-in-connected-manufacturing/


1. Monitoring lubricants & filters in hydraulic valve production in Industry 4.0

The cleanliness of the oil used to test hydraulic valves after production must meet a specified ISO target code. In order to obtain valid test results, we had to improve the oil quality.

We retrofitted the test benches, with IoT gateways and connected sensors. This enabled existing machines to communicate and perform sensor-based monitoring of the testing medium. Together with our customer, we created a rule-based method to monitor the ISO cleanliness level of the oil. It is now possible to continuously monitor the processing units and use an automated system for maintenance tickets.

With this approach, our customer was able to transform a manual process into an automated process.


The benefits in detail:

Lower maintenance costs

Less complex manual testing

Increase in overall equipment effectiveness (OEE)


2. Quality management of the pressing process

Airbag control units are manufactured by mechatronic presses that assemble every component by mating. To gain a better understanding of these mating processes and how process parameters and product quality relate, we extracted the process data from the proprietary press control system. That way we were able to monitor and demonstrate the force and position of the pressing processes.

We used the data to define a template process which then served as a reference for each press in the production. This allowed a direct evaluation of every single pressing process, based on the raw data. In the past this was only possible with a downstream quality assessment.


The benefits in detail:

More process transparency

Increase in product quality


3. Harmonization of tightening processes

A Bosch Rexroth worker using a nut runner.

When production lines are scattered across the world, it is important that products should be of the same quality, regardless where they are manufactured. One of our customers faced this issue when it came to improving the overall quality of tightening processes.

Our approach in this Industry 4.0 project was to connect the nut runners in different production locations to centralized software. This made it possible to apply the same quality standards to processes in different locations.

The benefits in detail:

More process transparency

Better product quality


4. Centralized monitoring & automated ticket allocation -  Push notifications.

In this Industry 4.0 use case, we developed a centralized monitoring solution in collaboration with a manufacturer. Because there was no central management system for the machines, error messages were only displayed locally on the human-machine interface (HMI). This meant that workers had to wait by the machine and might overlook other important issues.

We decided to set up one centralized system to record and display all machine data. We also established a system that automatically creates maintenance tickets and allocates workers depending on the situation. The workers access this system using an Android app with push notifications.


The benefits in detail:

An optimized maintenance process

Cutting the cost of failures by implementing a transparent and consistent troubleshooting process


5. EDM cycle time monitoring

The challenge here related to the monitoring of an electrical discharge machining (EDM) process: The data on process parameters were stored in a database which was checked only once a day. We wanted to evaluate the data using a manufacturing execution system (MES). But since the machines were old, the expense of connecting them to the MES was not a cost-effective option.

Instead, we used a software connector to read out and display the data directly from the machine. That way we were able to evaluate the status and notify associates when deviations occurred. This also allowed us to check and service machines on demand.


The benefits:

Early detection of cycle time deviations

Increase in output


6. Cycle time monitoring of CNC machines

Monitoring the status of a CNC machine is particularly difficult. One of the biggest challenges which many large manufacturing facilities are facing is not being able to see what is going on at a granular level. In other words, monitoring is labor-intensive and often only provides limited insight into operations. Employees normally check the vibrations of the machines at predefined intervals. This fixed schedule means that a problem may go undetected for some time. It is also hard to calculate the cycle time of various machines and pinpoint where underperforming machines are affecting production.

We decided to connect sensors to each machine to collect information on its operating status and performance. These parameters were then centrally processed and displayed. This allowed us to analyze information in close to real time. We were thus able to trigger standardized machine checks to optimize production parameters.


The benefits:


Reduced machine downtime

Fault prevention thanks to an early warning system

Continuous improvement based on machine benchmarking and condition monitoring


7. Condition monitoring of cooling systems

Blocked pipes in a cooling system can lead to pump failure. We encountered this problem in a plant where there was one cooling system with four cooling pumps. There was no central monitoring of cooling performance over time.

We attached temperature and flow sensors to the cooling pipes to generate data. Then we defined limits for cooling power and flow.

The benefits:

Advance warning of pipe blockages

Less need for pump maintenance

Less plant downtime


8. Condition monitoring of cutting fluids

Managing cutting fluid involves measuring the concentration, dosage and addition of fluid, and documenting measurements. It can be a completely manual process which is not always ideal.

Using a digital refractometer, we were able to measure the concentration of cutting fluid. If air bubbles formed in the cutting fluid mixture, this rendered the measured values useless. These values then had to be deleted.

The benefits in detail:

Long-term documentation, which can be used to improve tool life and surface finish quality

Cost savings resulting from lower dosing and consumption of water-soluble cutting fluids

Compliance with cutting fluid tolerance


9. Product quality monitoring in paint shop

Painting can be a demanding task. Especially when it comes to complex-shaped items like car windshield wiper arms. This means that a paint shop has to deal with a varying degree of quality when it comes to their paint jobs.


By integrating the IoT  into the process, we enabled our project partner to collect production data. This helped identify three parameters of relevance to product quality: temperature, humidity and paint consumption. We then defined threshold values enabling alerts to be issued when quality parameters were out of spec.


The benefits:

Faster response time in case of quality deviations

Better product quality


10. Vibration monitoring for milling machines

Another Industry 4.0 use case is vibration monitoring in milling machines. By positioning sensors close to the machine it is possible to measure vibration and gather information about specific vibration patterns during cutting operations like milling or drilling. In this way process data is collected on a large scale and provides a unique “digital fingerprint” for every milling process. By comparing the measured roughness with the individual fingerprints you can see how the two sets of data correlate.


The benefits:

Alert system when milling process gets out if spec

Quick response time should a problem occur


Product Catalog Industry 4.0 at Bosch - PDF

This classification also reflects the systematic approach Bosch uses to create Industry 4.0-ready ... tools to implement machine monitoring cases on their own.

https://www.cmafh.com/enewsletter/PDFs/robert_bosch_produktkatalog.pdf



Ten years of Industry 4.0


Bosch Tools

https://www.bosch-professional.com/gb/en/service/downloads/catalogues/



10 years Industry 4.0 at Bosch

   


Happy 10th birthday, Industry 4.0!

 A path toward the factory of the future — one in which people and machines work together as the best kind of team, manufacturing products in a way that is transparent, efficient, and conserves resources. A factory where the only things that are static and fixed will be the floors, walls, and ceilings; everything else will be variable and flexible.


 story: Ten years of Industry 4.0 and Bosch

2011: The fourth industrial revolution gets a name


A smart factory with machines that are connected, communicate with each other, and organize themselves — with people at the center of it all, orchestrating more efficient, more flexible, and more customized production. Originally called “cyber-physical production systems,” this idea received a catchier name in 2011: “Industrie 4.0” (Industry 4.0). It is a project with the official go-ahead given by r the German government. The German term quickly takes hold around the world.


2012: Bosch senior executives takes over the chairmanship of the Industry 4.0 working group


From concept to development: chaired by Siegfried Dais, former deputy chairman of the board of management of Robert Bosch GmbH, and Prof. Henning Kagermann, president of acatech, the Industry 4.0 working group draws up initial recommendations for implementing a successful path into the fourth industrial age. They send their recommendations to the German federal government in October 2012. 


2013: From Industry 4.0 to technology “Invented for life”


“We must turn data into knowledge, and knowledge into benefits,” said Bosch CEO at the time Volkmar Denner at the ZVEI Annual Convention in 2013. The company is already using connectivity software in its own manufacturing operations, and is also developing its own software solutions for industrial processes. Its declared aim is to derive business models from the technical potential of Web 3.0 that will lead to a better quality of life. 

Bosch begins working in 2013 on the “Energy-efficient factory” project spearheaded by the Technical University of Darmstadt.


2014: Bosch premieres the world’s first robot coworker


A Bosch employee is working together with the APAS assistant. The sensor skin developed by Bosch enables a contact-free cooperation of man and machine.

The world’s first robot certified to work side by side with human operatives without the need for additional protective housing comes to life at Bosch in 2014. Its name describes its purpose: APAS — automatic production assistant. This is not only a big step in the development of human-robot collaboration (HRC), but also a crucial one for Industry 4.0. Bosch has developed APAS so that it can autonomously take over the feeding of machines, palletizing, and assembly in the shortest possible time.


2015: Bosch establishes “Connected Industry”


Bosch pools its connected manufacturing expertise in its company-wide “Connected Industry” innovation cluster. This brings the company a step closer to becoming the leading user and leading supplier in connected manufacturing. Bosch launches an education intitaive: associates without a degree are to be offered training for IT and commercial jobs.  The aim is to respond to the growing demand for software expertise and prepare its workforce for Industry 4.0 jobs. The first group to participate in the program is made up of roughly 80 skilled workers.


2016: Bosch readies old tech for Industry 4.0


Retrofitting Old machines will give rapid connectivity and  benefits. This is the reasoning behind Bosch’s decision to add sensors to its company founder’s 130-year-old lathe. Sensors and software combined with IoT-enabled industrial control catapult the lathe from 1887 into the Industry 4.0 era.  According to studies in 2016, tens of millions of machines are still being assembled in plants worldwide without being enabled for Industry 4.0.


2016: Industry 4.0 on cloud nine — Bosch’s own cloud for IoT services


Launched its own cloud for internet-based services.  Bosch becomes a full-service provider for connectivity and the internet of things. In the Bosch IoT Cloud, the company runs various applications for its connected mobility, connected industries, and connected buildings businesses.


2017: Robots become colleagues


People and APAS robots share the workplace

With the APAS workstation, Bosch creates the first workplace where people and machines work side by side. People remain indispensable as decision-makers and drivers, supported by the precision and endurance of the production assistants. In this setup, Workplace 4.0 adapts to the individual — everything from the height of the work surface to the speed or guidance assistance for new processes.


2018: Bosch establishes Industry 4.0 operating unit


Bosch creates a new operating unit for connected industry. This brings together all its Industry 4.0 activities, especially concerning software and services. It also ensures that the company has the best possible team for the job: customers wanting to connect the entire value stream can now consult the new unit for support. The unit launches with 500 associates in Germany, Hungary, and China.


Bosch added its plant in Wuxi, China, to the list of shining examples - Industry 4.0 Lighthouses  in 2018.


2019: Bosch counts on training — and a smartphone for manufacturing


Developed by Bosch and the Chamber of Industry and Commerce, the first Germany-wide vocational training program geared to the Industry 4.0 skill set is launched. The training program is now also offered in other countries, such as China. That same year, Bosch debuts a new software solution: CtrlX AUTOMATION — ctrl being short for ’control.“ The solution makes systems and machines as accommodating as a smartphone, with functions that can be customized and updated — much the way a smartphone is via apps.


2020: Bosch puts first 5G campus network into operation


Data is transferred extremely reliably and ultra-fast, machines react almost instantaneously, wireless is becoming the standard, and people and machines work together safely and without barriers at all times — the new reality at the Bosch plant in Stuttgart-Feuerbach. This is the beginning of the real-time revolution for Industry 4.0 at Bosch, as it aims to gradually roll 5G out to all its roughly 240 plants around the world.


2020: Bosch’s pioneering Industry 4.0 role helps make its global manufacturing operations carbon neutral


The energy management platform records and analyzes energy flows at the Homburg plant.

All 400 Bosch locations worldwide no longer leave a carbon footprint. Connected manufacturing has played a crucial part in this achievement: Industry 4.0 solutions can detect energy consumption and make it more efficient. In over 100 plants and locations worldwide, Bosch is already utilizing an energy platform that is part of its own Industry 4.0 portfolio. Intelligent algorithms help predict energy consumption, avoid peak loads, and correct deviations in energy consumption.


2021: Toward zero-defect production with AI



The Bosch Center for Artificial Intelligence (BCAI) has developed a system based on artificial intelligence (AI) that can detect and remedy anomalies and malfunctions in the manufacturing process at an early stage. This use of AI ensures more efficient, environmentally friendly manufacturing with better products. The AI solution currently supports production in around 50 plants and 800 production lines, and will eventually be rolled out to all 240 Bosch plants.


2021: Bosch plant receives honor from World Economic Forum


For the second time, the World Economic Forum has honored a Bosch plant as an Industry 4.0 lighthouse project. In Suzhou, China, Bosch demonstrates how digitalized manufacturing and logistics can increase efficiency and quality in equal measure. Bosch already added its plant in Wuxi, China, to the list of shining examples back in 2018. There, the World Economic Forum highlighted the capability of connected solutions for troubleshooting and predictive maintenance as exemplary for a factory of the future.


2021: Bosch generates four billion euros in sales with Industry 4.0


Since launching Industry 4.0 ten years ago, Bosch has generated more than four billion euros in sales with its portfolio in this area. In 2020 alone, the company recorded sales of more than 700 million euros with connected solutions for manufacturing and logistics. Bosch is not only a leading supplier, but also a leading user: Bosch plants now count more than 120,000 machines and over 250,000 devices that feature connectivity, such as integrated camera systems and robots. Bosch projects indicate that connected solutions increase productivity by as much as 25 percent.


https://www.bosch.com/stories/10-years-industry-4-0-at-bosch/




Industry4.0 - Case study from Bosch

YouTube · Bosch India

7 Sept 2015

https://www.youtube.com/watch?v=ThNsNzC5ymA



Industry 4.0 - Digital Bosch plant in Blaichach, Germany

YouTube · Bosch Global

18 Oct 2018

Bosch India Pioneers "FACTORY OF THE FUTURE" for Indian Manufacturers: Viswamohan Y


Machine Maker

6 Apr 2025  

Bosch India is a leading supplier of technology and services in the areas of Mobility Solutions, Industrial Technology, Consumer Goods, and Energy and Building Technology. Established in 1951, Bosch India has grown to include 17 manufacturing sites and seven development and application centers across the country.


At the Bharat Mobility Expo 2025, Bosch India showcased its cutting-edge digital manufacturing solutions at the Auto Components Show organized by ACMA. In an exclusive interview with Hari Shanker of Machine Maker, Viswamohan Y, DGM of Business & Manufacturing Strategy Development, highlighted Bosch's journey towards Industry 5.0 and the implementation of advanced technologies such as digital twins and AI-based systems. He emphasized the importance of a lean production system, which Bosch has perfected over 15 years, to ensure seamless integration and efficiency across their factories.


Bosch's Factory of the Future initiative, particularly in their Bidadi and Nagnathpura plants, aspires to achieve the status of World Economic Forum Lighthouse Factories. These facilities have self-learning robots and AI-based camera systems that enhance reliability and efficiency in high-stakes production environments. Viswamohan Y demonstrated how these technologies optimize supply chain management and variant handling, ensuring high accuracy and productivity.


Recognising the challenges faced by small and medium-sized enterprises (SMEs) in adopting digital solutions, Bosch India is committed to supporting these businesses through modular and investment-friendly approaches. By providing digital readiness assessments and tailored solutions, Bosch helps SMEs transition smoothly into the digital era. This collaborative effort will strengthen the supply chain and boost the overall competitiveness of the Indian manufacturing sector.

https://www.youtube.com/watch?v=eD1Q75hdp0Q


Industry 4.0 -- from vision to implementation

YouTube · NEXT Conference

6 May 2014


Industry 4.0 – From vision to implementation


NEXT Conference

  6 May 2014  

Dive into the future of industrial transformation with Dr. Dirk Slama from Bosch Software Innovations GmbH! 🌍✨


In this insightful talk, Dr. Slama explores:

✅ Industry 4.0, Smart Factories, and the Industrial Internet

✅ The key drivers behind the global industrial revolution

✅ How communication, planning, logistics, and production are evolving

✅ Real-world business cases and overcoming potential obstacles

✅ Cutting-edge projects in the Bosch ecosystem shaping next-gen production systems


Whether you're interested in smart manufacturing, IoT, or the future of global supply chains, this talk provides valuable insights into the transformation of the industrial landscape.

https://www.youtube.com/watch?v=1vZYvAcU8hY



Hybrid Advances

Volume 7, December 2024, 100277

Hybrid Advances

Review Article

AI revolutionizing industries worldwide: A comprehensive overview of its diverse applications

https://www.sciencedirect.com/science/article/pii/S2773207X24001386



Industry 4.0 solutions from Bosch Rexroth

From fast, high-precision image processing assistants to safe, collaborative robots, you will accompany our products into the transformable Factory 4.0.

https://www.boschrexroth.com/en/hu/industries/industry-4-0-solutions/

https://www.boschrexroth.com/en/hu/academy/industry-4-0-trainings/

Bosch combines Industry 4.0 with AI


Bosch Media Service


3 Mar 2021 — This software solution uses AI to control and optimize energy flows in manufacturing operations. In addition to boosting energy efficiency, it ...

https://www.bosch-presse.de/pressportal/de/media/dam_images/pi11290/pi11290_en.pdf

https://www.bosch-presse.de/pressportal/de/en/news/factsheet/industry-4.0/


Bosch's top 10 uses of industry 4.0 in manufacturing


Medium · Georgia Wilson

3 years ago

With industry 4.0 changing the ways in which manufacturers operate around the world, we look at Bosch's top 10 use cases of innovative ...

https://medium.com/@georgia.wilson/boschs-top-10-uses-of-industry-4-0-in-manufacturing-351b63843c4c


Use cases/prototypes

Bosch Global

https://www.bosch.com/research/research-fields/digitalization-and-connectivity/economy-of-things/


The company's role in the project is to ensure a strong practical focus on industrial manufacturing processes. Firstly, this means developing an Industry 4.0 ...


Industry 4.0: Predictive maintenance use cases in detail


Bosch Digital Blog

https://blog.bosch-digital.com › industry-4-0-predictive...

Industry 4.0 impacts maintenance processes as the opportunity to carry out predictive maintenance arises. Our use cases show, what this means in practice.


How Bosch is driving Industry 4.0 in India

Computer Weekly

https://www.computerweekly.com › news › How-Bosch...

5 Dec 2022 — Bosch India is leveraging advance analytics and artificial intelligence to detect manufacturing defects and plans to tap quantum computing ...



Bosch Connected Industry

https://www.bosch-connected-industry.com › ...

In all cases, Bosch Connected Industry is your ideal partner! ... This is Industry 4.0. ... Industrial Application System. Systematic Production Improvement for ...


COVER STORY

Bosch in India

https://www.bosch.in › our_company › stories_1

PDF

The use case depends on the business case and return on investment. Smart copy between plants is encouraged to co- create the Factory of the Future. In terms of ...

2 pages


Manage your Factory Remotely

Bosch Global Software Technologies

https://www.bosch-softwaretechnologies.com › manage...

5 May 2024 — Remote factory management and monitoring can be applied in several use cases to drive delivery excellence across production, asset maintenance, ...


Bosch I4.0 Use Cases

OntoCommons.eu

https://ontocommons.eu › 2023-04-04-Bosch-Case

PDF

Use case DOME4.0 and OntoCommons. Lessons learnt for ontology-based commons: Semantically Empowered Industry 4.0 @Bosch. Evgeny Kharlamov, Bosch AI. 


Industry 4.0 at Bosch: the power of an idea

Bosch Media Service

https://www.bosch-presse.de › pressportal › industry-4-...

27 Nov 2018 — Recognizing workers, avoiding collisions – production assistants such as APAS from Bosch allow humans and machines to work safely side by side, ...


Bosch Connected Industry

https://www.bosch-connected-industry.com › news › us...

NEXEED in action · Managing injection molds 4.0 · Optimal use of milling tools · Optimization of tightening processes · Fewer rejects during leak testing.


Building an Industry 4.0 Analytics Platform

christophgroeger.de

https://www.christophgroeger.de › download › Gr...

PDF

by C Gröger · 2018 · Cited by 124 — is detailed in Section 4 regarding use cases ... practical application area of the Bosch Industry 4.0 Ana-.


Data based decision-making: Industry 4.0 packages

Bosch Rexroth

https://www.boschrexroth.com › industry-4-0-solutions

Join us in the world of industrial digitalization and choose the Industry 4.0 package that suits you best, allowing you to make data-driven decisions ...


Digital Transformation in Manufacturing through the lens of Bosch Global Software Technologies

https://www.bosch-softwaretechnologies.com › digital-t...

“Industry 4.0 has helped Bosch reimagine manufacturing with “factories of the future.” By realizing the significance of stock management for cash liquidity, we ...



The Case of Bosch Industry and Trade Corporation


ResearchGate

https://www.researchgate.net › ... › Trade

30 Jun 2020 — The Impact of Industry 4.0 Applications on Production Processes: The Case of Bosch Industry and Trade Corporation ; companies can easily ...


Bosch Industry Consulting: Home


Bosch Industry Consulting

https://www.bosch-industry-consulting.com › ...

Bosch recognized the relevance and potential of Industry 4.0 at a very early stage and was able to accumulate a wealth of experience in internal and external ...


Case Study - Bosch Rexroth and VIMANA Solution.

govimana.com

https://govimana.com › case-study-bosch-rexroth

Bosch Rexroth and VIMANA provided a total Industry 4.0 solution, harnessing real-time data for analysis that improved asset performance and productivity. As a ...


Industry 4.0: 7 Real-World Examples of Digital ...

AMFG

https://amfg.ai › 2019/03/28 › industry-4-0-7-real-worl...

28 Mar 2019 — IIoT has many use cases, with asset management and tracking being one of the major applications of the technology today. For example, IIoT ...


Bosch Adds Artificial Intelligence to Industry 4.0


Plastics Technology

https://www.ptonline.com › news › bosch-adds-artificial-...

1 May 2021 — The pilot user of the AI analysis platform is Bosch's Mobility Solutions business sector. Its plants using the system are already saving €1 ...


How Bosch uses AI in manufacturing - A foray through our ...

LinkedIn · Tobias Grocholl

3 months ago

Many Bosch plants have one thing in common: not only are they AI pioneers, but they also focus consistently on Industry 4.0. For example, Bosch ...


Bosch To Use Generative AI In Manufacturing


Metrology and Quality News

https://metrology.news › bosch-to-use-generative-ai-in-...

11 Dec 2023 — Now we're combining Industry 4.0 with artificial intelligence: connected manufacturing provides data and AI evaluates it,” Rueckert says. Errors ...


Qualcomm and Bosch Rexroth Showcase Industrial ...


Qualcomm

https://www.qualcomm.com › news › releases › 2022/02

27 Feb 2022 — ... applications for Industrial Internet of Things (IIoT) ... The technologies in the system can be applied to a range of use cases in Industry 4.0 to ...


A Big Data system supporting Bosch Braga Industry 4.0 ...

ScienceDirect.com

https://www.sciencedirect.com › article › abs › pii

by MY Santos · 2017 · Cited by 232 — Abstract · Introduction · Section snippets · Industry 4.0 and the factories of the future · Business intelligence and Big Data analytics evolution · Big Data ...


Bain and Bosch help automaker build new plant

https://www.bain.com › client-results › bain-and-bosch-...

Bain and Bosch Industry Consulting teamed up to help the automaker company ... Bain and Bosch Industry ... use cases to apply the latest Industry 4.0 technologies.


Bosch Connected Industry

Share2Perform

https://www.my.share2perform.com › web › content

PDF

Which use cases have synergies at the plant? Use Case Assessment. Maturity. KPIs & Pains. • What is the actual state of Industrie. 4.0 concerning specific use ...


Hans Michael Krause Bosch Rexroth AG - ManuFuture

manufuture2017.eu

http://manufuture2017.eu › uploads › 2017/10

PDF

Industry 4.0 at Bosch. G3/PJ-CI4 | 02/01/2017 ... Use Case: IoT Gateway at Bosch Rexroth. Production ... applications for industrial property rights. 24. Connected ...


Combining AI and IoT in manufacturing -  BOSCH ...

LinkedIn · Tobias Grocholl

 1 year ago

The key factor for smart factories and Industry 4.0 is the data that arise from the use of intelligent and networked products, the interaction ...


A Big Data system supporting Bosch Braga Industry 4.0 ...

ResearchGate

https://www.researchgate.net › publication › 31911497...

Joining volume, variety and velocity of data, with Industry 4.0, makes the opportunity to enhance sustainable innovation in the Factories of the Future. In this ...


Bain & Company, Bosch Connected Industry combine their ...


https://www.bain.com › about › bain-bosch-partnership

24 Sept 2018 — Together, Bain & Company and Bosch Connected Industry have compiled more than 150 use cases for digitalization. Customers benefit from the ...


Industry 4.0 live at Bosch

Malaysia IoT Association

https://www.my-iot.org › uploads › 2018/11 › 5-...

PDF

 i4.0 use cases and benefits – examples. Power / Energy. Management. ✓ peak reduction. ✓ energy cost saving.


Use cases - Bosch IoT Rollouts


Bosch IoT Suite

https://docs.bosch-iot-suite.com › rollouts › Use-cases

Bosch IoT Rollouts offers software updates for IoT use case – from single devices to large-scale campaigns. Software updates for devices in the Internet of ...






Bosch intensifies its industry 4.0 strategy


HANNOVER MESSE

https://www.hannovermesse.de › news › news-articles

Bosch's own factories also serve as a test environment for digitization technologies, which can then be made available to customers. By means of smart ...


Expertise i4.0


Bosch Industry Consulting

https://www.bosch-industry-consulting.com › article-1-dr...

Real-time data is the raw material of Industry 4.0. The possibilities to use this data for manufacturing companies are almost limitless. At the same time ...


Industry 4.0 - Focus on 3 use cases

YouTube · Nexans

5 months ago

To thrive in the fourth industrial revolution, driven by digitization of manufacturing businesses, Nexans has initiated a digital ...


Bosch Group boosts automation and productivity with ...

SUSE

https://www.suse.com › success › bosch-group-digital-tr...

Aligning its strategy with digital transformation processes, Bosch Group is focusing on innovative, service-based business models and the Internet of Things 



Industry 4.0: Predictive maintenance use cases in detail

Bosch Digital Blog

Industry 4.0: 7 Real-World Examples of Digital Manufacturing ...



AMFG

Bosch's top 10 uses of industry 4.0 in manufacturing | by ...


Medium




The Internet of Things and the case of Bosch: Changing ...

ScienceDirect.com

https://www.sciencedirect.com › science › article › pii

by AK Leiting · 2022 · Cited by 16 — Our analysis further shows that these two company values had a particularly strong impact in how Bosch changed its business model to become an IoT provider.


Bosch Connected Industry and Capgemini


https://www.capgemini.com › Home › Press Releases

27 Sept 2021 — The collaboration between two leading providers of Industry 4.0 software and services will create a broad range of offerings, from which ...


Nokia and Bosch

Nokia

https://www.nokia.com › We are Nokia

21 Feb 2023 — ... Industry 4.0 use cases. The two have deployed the proof of concept in a Bosch production plant in Germany, where extensive tests under ...


Bosch Boosts Factory Efficiency Through Smarter Data Use


Splunk

https://www.splunk.com › customers › success-stories

Bosch Boosts Factory Efficiency Through Smarter Data Use ... Manufacturing for Bosch's advanced lambda sensors required up to three weeks lead time and many ...


Digitalized intralogistics and manufacturing

IoT Use Case

https://iotusecase.com › Home › Podcasts

Bosch Connected Industry is the IIoT software house of Bosch. In line with Bosch's lead user and lead provider strategy, the software and services under the ...


Bosch: Industry 4.0 can increase productivity by up to 25 percent

boschmediaservice.hu

https://www.boschmediaservice.hu › press_release › bos...

8 Oct 2020 — “We are not only improving factory productivity, but also enabling companies to respond quickly and appropriately to changes.” To take the ...


Bosch wants to make billions with Industry 4.0

HANNOVER MESSE

https://www.hannovermesse.de › news › news-articles

The technology corporation began systematically connecting manufacturing and logistics in 2012. And its investments are starting to pay off.


Knowledge Graphs and Semantic Web: 5th Iberoamerican ...

google.co.in

https://books.google.co.in › books

Fernando Ortiz-Rodriguez, ‎Boris Villazón-Terrazas, ‎Sanju Tiwari · 2023 · ‎Computers

 Industry 4.0 applications. This approach's most ... Bosch manufacturing data, specifically the data required ...



----------------------------------


Sreekanta Aradhya. B 

Global Head of Practice -Bosch - Industry 4.0 

Bengaluru - India


Strategy & Growth I Digital Transformation I Thought leadership


Practice head in Industry 4.0 with senior level experience of 29+ years in the areas of Delivery management, Account, Program management, Bid management, Software development across Manufacturing, Oil & Gas , CPG industry verticals. 

I have an excellent track record of Growing Profitable Business, conceptualizing Strategic solutions and Developing innovative products .

https://www.linkedin.com/in/saradhya/?originalSubdomain=in



---------------------

A to Z Blogging Challenge Post















Ud. 17.7.2025, 19.5.2024
Pub. 2.4.2024



Wednesday, July 16, 2025

Make Technical Mastery An Expectation of the Organization - Invest in Learning and Development

In studying manufacturing over the past two decades, we have learned that operational excellence is not achieved by just applying so-called “lean” practices to every process. It requires cultivating an aptitude and an expectation for continuous improvement within every employee.

Similarly, we learned from studying lean product development that people, not processes, make great products.  We frequently encounter managers who think improvements in the development process will pay off in better products. But better products  are created by developers working with better knowledge and supported by good design processes.


Tasks for Managers for Improving New Product Development


Several steps can be taken to advance the development of  NPD people.

Make technical mastery an expectation of the organization and build it into the reward system. Toyota has made developing “towering technical competence” central in grooming new engineers and made mentoring fundamental to engineering leadership requirements.  Ford Motor Co. created  a technical maturity model for each functional area within body and stamping engineering and supported it in the way the company made job assignments, ran design reviews, and rewarded its engineers. Individuals were assessed on their technical capabilities according to the model, and then plans were made to increase the individual’s technical maturity and were incorporated into the individual’s performance evaluation. This created a strong incentive to  to build deeper expertise, for which they were rewarded subsequently.

Second, you should develop design standards and use them. Develop and use design guides as the starting point of the next development project. Once you have design standards, you need to systematically update them based on the learning gained on each development project. Toyota and other companies set aside one to two weeks of the development project timeline to pause and reflect on what they have learned on the current project that should be incorporated into their design standards, and then they do the additional development work to codify that learning into a reusable format. Somebody has to  own the design standards development process. The group of people who will be using them also must have a role  to ensure that they are easy to use and relevant.

Regular (for example, weekly) technical design reviews with the explicit aim of developing people through action learning and cross-functional collaboration have to be held. Some of the key questions issues to be discussed are: (1) What is the design standard used for the particular component, device or test? (2) What is the improvement in the the current design compared to standard? and (3) Where are the data to prove the claimed improvement?

Fourth, ask the following questions about the organization’s formal development process.

Who is responsible for deeply understanding the customer, creating the system architecture, and coordinating efforts to ensure that all decisions align with customer interests?

What problems does the solution intend to solve for the customer, and what additional value should the company offer?

To what extent  fixed aspects of the design (where no deviation from standard) versus the flexible aspects?

Are tricky and challenging issues identified early and efforts to put to solve them?

Are you investing enough resources to investigate the flexible areas?

Does that phase conclude with enough clarity and certainty about the remaining challenges of the project?

To what extent do process checkpoints encourage learning as opposed to meeting requirements or task lists?

Do you have the right number of checkpoints, do they occur at the right points in time, and are the right people involved?

Finally, you should take stock of the leadership culture within the organization. To support learning, ask the leadership team to focus  on instructing and improving. Design and manufacturing standards (what we currently know about the product and the technical processes) are the main tools for deepening the organization’s understanding of products and production processes. Encouraging problem-solving to resolve performance gaps with standards deepens the autonomy and insight of the responsible developers. Developer capacity is further enhanced by asking revealing questions about what people should be learning and how they are learning it.

Great people make great products. The explicit aim of new product development process has to be to grow better developers, who are increasingly knowledgeable and capable of solving problems and generating new solutions. People and people systems are also the most important parts of a product development system, because people generate the knowledge necessary for innovation, and people apply that knowledge to designs for new products, new manufacturing systems, and more robust supply chains.   (Rewrite once again)
http://sloanreview.mit.edu/article/why-learning-is-central-to-sustained-innovation/

Process Quality Control - Turtle Diagram Evaluation Model

 


Quality Control in Production Process of Product-Service System:a Method Based on Turtle Diagram and Evaluation Model Hongfei Guoa,b , Ru Zhanga,c, Xiangyue Cheng, Zhengwei Zouf*, Ting Qua,b, Guoquan Huanga,b, Jincheng Shi g, Minshi Chena,b, Hao Gua, Yitao Luna,b, Jianke Lid, Zhihui Hee

The research on process quality control in the field of quality management has been fruitful,which showsthat the feasibility and validity of process method in quality management 


According to the theory of process method analysis, the quality control of sub-process is to identify the sub-process elements by using the process analysis tool -turtle diagram analysis. 



















Smart Factory and Smart Manufacturing - Concept and Research - Articles and Papers



2013

The Dawn of the Smart Factory
Travis M. Hessman
FEB 14, 2013

Siemens Electronic Works - Amberg, Germany - Illustration of a High-mix, Low-volume facility


The Siemens (IW 1000/34) Electronic Works facility in Amberg, Germany, is a plant straight out of that dream. The immaculate, 108,000-square-foot high-tech facility vibrates with efficient, digital wonder as its smart machines coordinate the production and global distribution of the company’s Simatic control devices -- a custom, built-to-order process involving more than 1.6 billion components for over 50,000 annual product variations, for which Siemens sources about 10,000 materials from 250 suppliers to make the plant’s 950 different products.

2017
2017

Smart factory is a key concept that emerged in developments based on  the vision of Industry 4.0. It utilises a set of advanced technologies (including Internet of Things (IoT), cyber physical systems (CPS), cloud computing, big data and artificial intelligence) to enable peer-to-peer communication and negotiation between machines, systems and products, as well as to respond to constantly growing amount of data generated in manufacturing processes (Davis et al., 2015). As a result, smart factory addresses vertical integration of different components and facilitates the factory to reconfigure itself for flexible production of different types of products (Lopez Research, 2014).

Smart factory is a term used to describe industrial operation improvements through integration and automation of production systems, linking physical and cyber capabilities, and maximising data power including the leverage of big data evolution (Moyne and Iskandar, 2017).

By applying IoT technologies (e.g. wireless sensors, RFID tags, CPS, etc.), smart factory can monitor real-time machine processes in the production line, create a virtual copy of its physical world and finally lead to a shift from centralised control system to new forms of decentralised, distributed and autonomous control and operations (Zhong et al., 2017).

Companies initiating smart factory innovation seek to obtain competitive advantages through adopting and applying cutting-edge information technologies (Kang et al., 2016).

This brings in many benefits including flexibility (Veza et al., 2015), productivity and resource efficiency (furthermore, Kolberg and Zühlke, 2015).

In organisational practice, pioneers and practitioners pursuing leading-edge smart factory initiatives are actively leveraging big data solutions like  SAP Hana for optimising operations and automation on a real-time basis (Zhong et al., 2016).



A review of the literature on smart factory showed that current research studies on smart factory could be categorised into three streams.

The first stream concentrated on proposing general system architectures and engineering solutions by analysing the requirements of smart factory, in order to bring smart factory from a concept into technical practice (e.g. Lee et al., 2015; Lin et al., 2018).

The second  set of research is focused on  pilot applications and technical prototypes of smart factory in particular industries, such as automobile and aircraft manufacturing industry (e.g. Zhong et al., 2016), petrochemical industry (e.g. Li, 2016; Yuan et al., 2017) and green energy industry (e.g. Shrouf et al., 2014).

The third group of studies attempted to explore potential challenges and risks associated with smart factory more  from a  specific  perspective, e.g. information security issues (Lasi et al., 2014) and information access and process issues (Dhungana et al., 2015).

Source

Shuyang Li, Guo Chao Peng and Fei Xing (2019) "Barriers of embedding big data solutions in smart factories: insights from SAP consultants", Industrial Management & Data Systems, Vol. 119 No. 5, pp. 1147-1164
https://www.emerald.com/insight/content/doi/10.1108/IMDS-11-2018-0532/full/html


2020

Implementing the smart factory: New perspectives for driving value
By Gérald Faustino, National Leader, Aerospace & Defence, Deloitte Canada
27 Jul. 2020

86 percent of surveyed manufacturers say smart factories will be the main driver of competitiveness in five years. Only five percent operate a fully converted facility. (It means companies are receptive to listen to proposals of consultants, hardware suppliers and software suppliers.)



2021

Appropriate Smart Factory for SMEs: Concept, Application and Perspective (Interesting and appropriate paper)

Woo-Kyun Jung et al.
International Journal of Precision Engineering and Manufacturing volume 22, pages201–215 (2021)
Open Access

A vision based quality arrangement (Illustration of low cost smart system)

Hardware Configuration

The Raspberry Pi was selected as the IoT computer, because it is relatively inexpensive and can satisfy the requirements.  The work conducted on the sewing machine was filmed using a small camera. Then, after image processing and fault detection on a small computer, an alarm was sounded by the appropriate IoT in the case of a defect. 

Software Configuration
The sewing inspection algorithm was designed to be run at a small-data level using a small IoT computer. Algorithms were established for processing and judging image data collected from the hardware using OpenCV and Python, which are open-source solutions for image processing.

The complete system, including a computing unit and cameras, can be configured for ≤ 170 USD. 



Smart automation


Innovate through smart automation for all your manufacturing needs. Connect machines and processes from the engineering stage all the way to the shop floor and beyond. Automate your shop floor to run at maximum output and efficiency, saving you time, reducing cost, and maximizing your labor force.

Smart Factory at Audi
Good information on Audi's initiatives and progress
01/22/2021

Jan 21, 2021
Smart Factory Transformation: The Time Is Now
Vincent Rutgers, Deloitte

Smart Manufacturing Platform Market


Smart Manufacturing Platform Market with COVID-19 Impact by Type (Device Management, Connectivity Management, Application Enablement Platform), Application (Performance, Optimization, Asset & Condition Monitoring), Industry, Region - Global Forecast to 2026

https://www.marketsandmarkets.com/PressReleases/smart-manufacturing-platform.asp

https://www.persistencemarketresearch.com/market-research/smart-manufacturing-platform-market.asp


Open Access

Six-Gear Roadmap towards the Smart Factory

by Amr T. Sufian 1,*,Badr M. Abdullah, Muhammad Ateeq, Roderick Wah  and David Clements 2

Faculty of Engineering and Technology, Liverpool John Moores University, Liverpool L3 3AF, UK
Beverston Engineering Ltd., Prescot L34 9AB, UK

Appl. Sci. 2021, 11(8), 3568; https://doi.org/10.3390/app11083568



2024


2025

Innovating smart manufacturing solutions
We help our customers solve their manufacturing challenges with our next-generation smart manufacturing solutions. Leveraging the latest technologies and powerful accelerators, we drive innovations that digitize the manufacturing value chain, enabling our clients to deliver better products with enhanced operational efficiency.


CII Manufacturing Competitiveness Study: Paving the Way for India’s Smart Manufacturing Future

2025 Smart Manufacturing and Operations Survey: Navigating challenges to implementation
Deloitte’s survey of 600 executives.

With its ability to capture and integrate data from across facilities fueled by automation and analytics, smart manufacturing and operations (also called “smart factories”) can answer the many stubborn challenges related to capacity and competitiveness.  “Industry 4.0” has been making ambitious promises for years, but the moment of value realization is finally arriving.




------------------------------------------------------------------


Related Posts

High Productivity Through Smart Factories - Industry 4.0 - Bulletin Board  

Data Analytics Period in Productivity Improvement - Productivity Engineering and Management

Productivity Improvement Through Smart Machines

Productivity Improvement Techniques and Industry 4.0 Technologies - Interface and Integration

Productivity Improvement - “Industry 4.0, Leapfrog Opportunity for India” - Productivity Week Theme - India 2018

Applied Industrial Engineering  - Industrial Engineering 4.0 - IE in Industry 4.0 Engineering Systems and Processes #IndustrialEngineering #IE40 #Industry40

Industrial Engineering & ISE - Engineering & Technology, Process, and People



Updated 16.7.2025, 13.9.2022,  5 July 2021
Pub 15 July 2019












Smart Factory and Smart Manufacturing - Productivity Improvement




Productivity Improvement Achieved by Best Practice Companies.

Read the information available on each plant to become aware of the effective use made by these companies of Industry 4.0 Technologies in various processes and systems.



Apple Inc. - Industrial Engineering Activities - Industrial Engineering 4.0


Bosch Automotive - Bursa - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


CEAT - Halol, India Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant.


4. Dr Reddy's - Hyderabad Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


5. .Ericsson - Lewisville Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

6. Foxconn - Shenzen Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


8. GlaxoSmithKline (GSK) Hertfordshire Plant - Industrial Engineering 4.0


9. Haier - Hefei Plant - Industrial Engineering 4.0 - Industry 4.0 WEF-McKinsey Lighthouse


10. Ingrasys - Taoyuan, Taiwan Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


11. Johnson & Johnson - Industrial Engineering - Productivity Improvement Activities - Industry 4.0 Lighthouse Plant


12. K-Water - Hwaseong - REPUBLIC OF KOREA - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant


13. LONGi Solar - Jiaxing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

15. Mondelēz - Beijing Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant
Mondelez - Sricity

16. Novo Nordisk - Hillerød Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

17. Otis - Industry 4.0 - Industrial Engineering 4.0 - Productivity and Quality Engineering and Improvement.


18. Procter & Gamble - Takasaki Plant - Industrial Engineering 4.0 - WEF - McKinsey Light House Plant

19. Quaker Houghton - Industrial Engineering 4.0 - Intelligent Die Casting

20. Renault - Industrial Engineering 4.0



22. S   Schneider Electric - Hyderabad

23. T  The Coca-Cola Company - Ballina

24. U  Unilever - Sonepat

25. V   Volkswagen - Industrial Engineering 

26. W   Western Digital - Bang Pa-In

27. X    Xiaomi Corporation - Industrial Engineering 4.0  - vacuum cleaner

29. Y   Yamaha - Industrial Engineering 4.0

30. Z   Zymergen - Emeryville




Monday, December 14, 2020
The Dimensions of the New MESA Smart Manufacturing Model

Technologies, capabilities and lifecycles. 

The New MESA Smart Manufacturing Model will  provide guidance to practitioners and provide a practical down-to-earth vision of what Smart Manufacturing can and should be.

http://blog.mesa.org/2020/11/the-value-of-new-mesa-smart.html

http://blog.mesa.org/2020/11/getting-new-mesa-smart-manufacturing.html

http://blog.mesa.org/2018/02/diiot-idiot.html

http://blog.mesa.org/2018/02/the-importance-of-standards-for-smart.html

http://blog.mesa.org/2017/12/is-industry-40-really-smart.html

http://blog.mesa.org/2017/11/the-smart-factory-shifts-from-reactive.html

http://blog.mesa.org/2017/08/virtual-smart-advisors-kickstart-smart.html

http://blog.mesa.org/2017/06/industry-40-and-smart-services-welt.html

http://blog.mesa.org/2017/05/notes-from-smart-manufacturing-and-iiot.html

http://blog.mesa.org/2017/04/top-3-drivers-for-mes-in-industry-40.html



http://blog.mesa.org/2016/07/how-smart-are-we-in-manufacturing-today.html

http://blog.mesa.org/2016/06/the-smart-manufacturing-landscape_30.html

http://blog.mesa.org/2016/03/smart-manufacturing-and-continuing-need.html

http://blog.mesa.org/2016/03/the-smart-manufacturing-elevator-pitch_25.html

http://blog.mesa.org/2016/03/the-smart-manufacturing-elevator-pitch.html

http://blog.mesa.org/2016/03/smart-manufacturing-isnt-so-smart.html

http://blog.mesa.org/2016/02/how-to-achieve-smart-manufacturing.html

http://blog.mesa.org/2016/01/smart-manufacturing-what-if-they-threw.html

http://blog.mesa.org/2015/04/join-development-of-smart-manufacturing.html  First post on smart manufacturing in MESA Blog



---------------
The Smart Factory - Deloitte Insights - 2019

Major features: connectivity, optimization, transparency, proactivity, and agility.

Each of these features can play a role in enabling more informed decisions and can help organizations improve the production process.


Benefits of the smart factory

Asset efficiency - productivity

Product Performance and Quality

Lower cost

Safety and sustainability


https://www2.deloitte.com/us/en/insights/focus/industry-4-0/smart-factory-connected-manufacturing.html


ud. 16.7.2025, 1.1.2021, 2 Jan 2020
posted 23.10.2019

Smart Manufacturing - Application Areas




23.6.2025




13.9.2022






Smart Manufacturing - Application Areas


  • Automatic changes to products on prod. line
  • Modelling and simulation
  • Digital direction setting
  • Rapid design prototyping through 3D printing
  • Digital twins – factory network
  • 3D scanning for quality
  • Advanced analytics platform
  • Mixed reality for maintenance work
  • Energy management through IoT
  • Lean digitization
  • Smart supply chain- Automated Guided Vehicles
  • Predictive maintenance through IoT
  • 3D Simulation for Production Line
  • Digital Assistant System for Operators
  • Implementation of Automation
  • Integration of ERP²/MES³/PLM


Connected Factories and The Future of Manufacturing: Challenges, Top Use Cases, and Benefits

Five uses cases for manufacturing a truly connected industry
Thomas Noren on Fri, 01/15/2021

Top 5 Big Data Use Cases in Smart Manufacturing
 VIVEK KUMAR,  May 8, 2020 




The Top 20 Industrial IoT Applications
Brian Buntz
20th September 2017

1. ABB: Smart robotics

Power and robotics firm ABB is one of the most visible to embrace the concept of predictive maintenance, using connected sensors to monitor its robots’ maintenance needs — across five continents — and trigger repair before parts break. Also related to IoT is the company’s collaborative robotics. Its YuMi model, which was designed to collaborate alongside humans, can accept input via Ethernet and industrial protocols like Profibus and DeviceNet.

 2. Airbus: Factory of the Future

Airbus has launched a digital manufacturing initiative known as Factory of the Future to streamline operations and bolster production capacity. The company has integrated sensors to tools and machines on the shop floor and given workers wearable technology — including industrial smart glasses — designed to reduce errors and bolster safety in the workplace. In one procedure, known as cabin-seat marking, the wearables enabled a 500% improvement in productivity while nearly eliminating errors.


3. Amazon: Reinventing warehousing


Amazon is “testing the limits of automation and human-machine collaboration.” While the company’s ambitions to use drones for delivery has won considerable media attention, the firm’s fulfillment warehouses make use of armies of Wi-Fi-connected Kiva robots. The basic idea behind the Kiva technology, which Amazon acquired for $775 million in 2012, is that it makes more sense to have robots locate shelves of products and bring them to workers rather than have employees go to the shelves to hunt for products. In 2014, the robots helped the company cut its operating costs by 20%, according to Dave Clark, a senior vice president at Amazon.

4. Boeing: Using IoT to drive manufacturing efficiency

Boeing and its Tapestry Solutions subsidiary have aggressively deployed IoT technology to drive efficiency throughout factories and supply chains. The company is also steadily increasing the volumes of connected sensors embedded into its planes.

5. Bosch: Track and trace innovator

In 2015, Bosch launched what would be the Industrial Internet Consortium’s first test bed. The primary inspiration behind the so-called Track and Trace program is that workers would spend a sizable amount of their time hunting down tools. So the company added sensors to its tools to track them, starting with a cordless nutrunner. As the resolution of the tracking becomes more precise, Bosch plans to use the system to guide assembly operations.

6. Caterpillar: An IIoT pioneer

It is using IoT and augmented reality (AR) applications to give machine operators an at-a-glance view of everything from fuel levels to when air filters need replacing. If an old filter expires, the company can send basic instructions for how to replace it via an AR app. The company’s marine asset intelligence division is also an innovator. Last year, Forbes ran an article explaining how the company used sensor-driven analytics to save a bundle of money on boats and shipping vessels.




7. Fanuc: Helping to minimize downtime in factories

Robotics maker Fanuc is serious about reducing downtime in industrial facilities. Using sensors within its robotics in tandem with cloud-based analytics, the company can predict when failure of a component such as a robotic system or process equipment is imminent. While predictive maintenance is a familiar concept, Fanuc has embraced it more aggressively than most. Last year, GM awarded Fanuc’s Zero Downtime (ZDT) system its Supplier of the Year Innovation Award.

8. Gehring: A pioneer in connected manufacturing

The company enables its customers to see live data on how Gehring’s machines work before they place an order. It does so by using digital technology, beaming real-time information from a new machine to a customer to ensure that it meets the customer’s requirements for precision and efficiency. Gehring uses the same cloud-based real-time tracking to reduce downtime and optimize its own manufacturing productivity through monitoring its connected manufacturing systems, visualizing and analyzing data from its machine tools in the cloud.

9. Hitachi: An integrated IIoT approach

It offers an IoT platform known as Lumada, Hitachi also makes a plethora of products leveraging connected technology, including trains, which the company is beginning to sell as a service. Hitachi has also developed an IoT-enhanced production model that it claims has slashed production lead times by half within its Omika Works division, which manufactures infrastructure for electricity, traffic, steel manufacturing and other industries.

10. John Deere: Self-driving tractors and more

 John Deere is  deploying Internet of Things technology —  with self-driving tractors.  The company also happens to be a pioneer in GPS technology. The most-advanced systems it uses in tractors are accurate to 2 centimeters. In addition, the company has deployed telematics technology for predictive maintenance applications.

11. Kaeser Kompressoren: Air as a service

 The company offers “digital twins” for its products and supports predictive maintenance. One of its best-known Industrie 4.0 efforts relates to its business model innovation as selling “air as a service,” 

12. Komatsu: Innovation in mining and heavy equipment

Komatsu has linked all of its robots at its central production facilities to the internet, enabling managers to keep an eye on international operations in real time. Its massive self-driving trucks can be spotted in Rio Tinto’s Mine of the Future in Australia. Komatsu recently acquired U.S. mining equipment maker Joy Global, which had developed connected longwall shearers for coal mining that can wirelessly send 7,000 data points per second to the company’s data center.

13. KUKA: Connected robotics

German robotics specialist KUKA has an IoT strategy that extends to whole factories. For Jeep,  it helped the company build an IoT-enabled factory with hundreds of robots linked to a private cloud. The plant can produce more than 800 vehicles each day.

14. Maersk: Intelligent logistics

The Danish shipping company has embraced the Internet of Things to keep track of its assets and optimize fuel consumption and the routes of its ships. The technology has proven to be especially useful for refrigerated containers, whose contents could spoil in the absence of tight temperature control.  Maersk has enlisted sensors and data analytics applications to inform how it stores empty containers and locates them. The company is using blockchain technology to optimize its supply chain operations further.

15. Magna Steyr: Smart automotive manufacturing

The company,  can precisely track assets ranging from tools to vehicle parts, automatically ordering a replenishment when necessary. Magna is also testing the use of “smart packaging,” enhancing it with Bluetooth, to help keep track of components in its warehouses. Autonomous vehicles within its facilities help ferry components through plants during assembly, optimizing routes dynamically. It uses wearable technology to help guide its employees in the production of bespoke vehicles. 

16. North Star BlueScope Steel: Keeping workers safe

Steelmaker North Star BlueScope Steel has deployed wearables in helmets and wristbands in a proof-of-concept project to help managers track employee safety and spot hazardous scenarios before they lead to injuries. The wearables also track health metrics such as body temperature, pulse and activity levels, enabling supervisors to give taxed workers a break when necessary. In addition, the steel producer is using connected sensors to monitor extremes in environmental temperature as well as the presence of radiation and toxic gases.

17. Real-Time Innovations: Microgrid innovation

RTI and a handful of partners have created innovative technology that divides the power grid into an array of microgrids that can each be managed independently. 

18. Rio Tinto: Mine of the Future

Driverless trucks and trains haul ore away from the mining sites while an autonomous drill technology enables a remote worker to oversee multiple drills from a single console. Driverless ships may be in its future as well. The company has a control center complex in Perth that connects to its mines as well as its rail and port operations, where engineers, analysts, programmers and technicians remotely guide mining operations.

19. Shell: Smart oil field innovator

Shell reports that its smart oil fields can obtain 10% more oil and 5% more gas than traditional fields.The company links its high-tech wells with fiber-optic cable that allows remote employees to monitor operations remotely. The company recently launched a digital twin initiative for an offshore rig in the southern North Sea.

20. Stanley Black & Decker: Connected technology for construction and beyond

The company’s smart factory program in Reynosa, Mexico, led to a 24% increase in production of routers used for woodworking. It uses radio signals to help monitor the location of tools, monitor construction progress and comply with OSHA rules. The company’s DeWalt division is also launching an initiative known as Construction Internet of Things, which will use an IoT platform to monitor workers and equipment across the job site. Already, DeWalt has debuted a connected battery service that can not only monitor battery levels but shut down tools if a thief attempts to remove them from a defined area.



Smart Manufacturing - Application Areas

Smart Inspection

Smart Material Handling and Transport

Smart Warehouse - Industry 4.0 Warehouse - Warehouse 4.0

Smart Production Planning - Smart Process Chart Improvement









Updated on  16.7.2025,  23.6.2025, 13.9.2022,  5.5.2022, 29.3.2022
Pub. 11.11 .2019