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Assembly system design in the Industry 4.0 era: a general framework

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DOI: 10.1016/j.ifacol.2017.08.1121

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Proceedings of the 20th World Congress
Proceedings of the
The International 20th World
Federation of Congress
Automatic Control
Proceedings
Proceedings
The of
of the
the
International 20th
20th World
World
Federation of Congress
Available
Congress
Automatic online at www.sciencedirect.com
Control
Toulouse,
The France,
International July 9-14,
Federation 2017
of Automatic Control
Control
The International Federation of
Toulouse, France, July 9-14, 2017Automatic
Toulouse,
Toulouse, France,
France, July
July 9-14,
9-14, 2017
2017
ScienceDirect
IFAC PapersOnLine 50-1 (2017) 5700–5705
Assembly
Assembly system
system design
design in
in the
the Industry
Industry 4.0
4.0 era:
era: aa general
general framework
framework
Assembly system design in the Industry 4.0 era: a general
Assembly system design in the Industry 4.0 era: a general framework
framework
,†
Marco Bortolini*, Emilio Ferrari*, Mauro Gamberi*, Francesco Pilati*,†, Maurizio Faccio **
Marco Bortolini*, Emilio Ferrari*, Mauro Gamberi*, 
Francesco Pilati*,,†, Maurizio Faccio **
Marco
Marco Bortolini*,
Bortolini*, Emilio
Emilio Ferrari*,
Ferrari*, Mauro
Mauro Gamberi*,

Gamberi*, Francesco Pilati* †,, Maurizio
Francesco Pilati* Maurizio Faccio
Faccio **
**

* University of Bologna, Department of Industrial Engineering, Viale del Risorgimento 2, 40136 Bologna, Italy
* University of Bologna, Department of Industrial Engineering, Viale del Risorgimento 2, 40136 Bologna, Italy
*
* University
University of Bologna,
of of
**University Padova,Department
Bologna, Departmentof
Department ofofIndustrial
Industrial Engineering,
Engineering,
Management Viale
Viale del
& Engineering, St.Risorgimento
del San Nicola 3,2,
Risorgimento 40136
2,36100 Bologna,
40136Vicenza,
Bologna, Italy
Italy
Italy
**University of Padova, Department of Management & Engineering, St. San Nicola 3, 36100 Vicenza, Italy
**University of Padova, Department
† of Management
Corresponding
**University of Padova, Department Author:
of Management & Engineering, St. San Nicola
francesco.pilati3@unibo.it 3, 36100 Vicenza, Italy
& Engineering, St. San Nicola 3, 36100 Vicenza, Italy
† Corresponding Author: francesco.pilati3@unibo.it
†† Corresponding
Corresponding Author:
Author: francesco.pilati3@unibo.it
francesco.pilati3@unibo.it

Abstract: Assembly system design defines proper configurations and efficient management strategies to
Abstract: Assembly system design defines proper configurations and efficient management strategies to
maximize
Abstract: the
Abstract: Assembly
assembly
Assembly system
system
system design
design defines
defines proper
performances. Beyond
proper configurations
assembly line
configurations and
and efficient
balancingmanagement
efficient and scheduling, strategies
several to
maximize the assembly system performances. Beyond assembly line balancingmanagement
and scheduling, strategies
several to
maximize
other
maximize the
dimensions
the assembly
of this system
assembly problemperformances.
system performances. Beyond
have to be considered.
Beyond assembly
Furthermore,
assembly line
line balancing
the assembly
balancing and
and scheduling,
system designseveral
scheduling, has to
several
other dimensions of this problem have to be considered. Furthermore, the assembly system design has to
other
other dimensions
consider the industrial
dimensions of
of this problem
problem have
environment
this have to
to be
in which be considered. Furthermore,
the system operates.
considered. Furthermore, the
the assembly
The latest industrial
assembly system design
revolution,
system designnamelyhas
has toto
consider the industrial environment in which the system operates. The latest industrial revolution, namely
consider
Industry
consider the
4.0,
the industrial
leverages
industrial environment
Internet
environment in
connected
in which
which the
and
the system
sensorized
system operates.
machines
operates. The
The tolatest industrial
manufacture
latest industrial revolution,
customer-designed
revolution, namely
namely
Industry 4.0, leverages Internet connected and sensorized machines to manufacture customer-designed
Industry
products.4.0,
Industry Thisleverages Internet
paper proposes
Internet an connected
originaland sensorized
framework machines
which to
to manufacture
investigates the impact customer-designed
of Industry 4.0
products.4.0, Thisleverages
paper proposes connected
an originaland sensorized
framework machines
which investigates manufacture
the impact customer-designed
of Industry 4.0
products.
principles
products. This
on paper
assembly proposes
system an
design.original
The framework
traditional which
dimensions investigates
of this the
problem impact
are of
of Industry
described 4.0
along
principles This paper proposes
on assembly an original
system design. The framework which investigates
traditional dimensions the impact
of this problem Industry
are described 4.0
along
principles
with the
principles on assembly
industrial
on assembly system
environment design.
system design.evolution The traditional
over
Theover the
traditional last dimensions
three centuries.of this problem
Concerning are
the described
latest along
industrial
with the industrial environment evolution the last dimensions
three centuries. of this problem are
Concerning the described
latest industrialalong
with
with the
the industrial
revolution, environment
the technology
industrial environment evolution
innovations
evolutionwhich over
over the last
last three
enabled
the the centuries.
three manufacturing Concerning
processthe latest
latest industrial
digitalization are
revolution, the technology innovations which enabled the centuries.
manufacturing Concerning
processthedigitalization industrialare
revolution,
presented.
revolution, The the
The technology
application
the application
technology of innovations
of these
innovations which
enabling enabled
technologies
whichtechnologies the tomanufacturing
the
enabled thetomanufacturing assembly process
domain digitalization
results in a are
new
presented. these enabling the assembly process domain digitalization
results in a new are
presented.
generation
presented. The
The application
of assembly
application of
systems,
of these
these enabling
the technologies
here defined
enabling technologies to
assembly
to the
the assembly
system
assembly 4.0.domain
Finally,results
domain in aa new
the distinctive
results in new
generation of assembly systems, the here defined assembly system 4.0. Finally, the distinctive
generation
generation of
characteristics of of assembly
these novel systems,
systemsthe are here
proposeddefined assembly
and described
assemblyin system
detail. 4.0. Finally, the distinctive
characteristics ofassembly
these novel systems,
systemsthe are here
proposeddefined and described insystem
detail. 4.0. Finally, the distinctive
characteristics of these novel systems are proposed and described in detail.
© 2017, IFAC
characteristics
Keywords: of these system,
(International
Assembly novelFederation
systems
Industry are proposed
of 4.0,
Automatic
Framework,and described
Control) Hosting
Design inanddetail.
by Elsevier Ltd. AllInternet
management, rights reserved.
of things,
Keywords: Assembly system, Industry 4.0, Framework, Design and management, Internet of things,
Smart
Keywords:
Keywords: Assembly
manufacturing,
Assembly system, system,
Assembly Industry
line
Industry 4.0, Framework,
balancing,
4.0, Framework, Modeling Design
of
Design and
assembly management,
and management, units, Internet
Process of
of things,
supervision,
Internetsupervision,things,
Smart manufacturing, Assembly line balancing, Modeling of assembly units, Process
Smart
Logistics
Smart manufacturing,
in manufacturing.
manufacturing, Assembly
Assembly line
line balancing,
balancing, Modeling
Modeling of
of assembly
assembly units,
units, Process
Process supervision,
supervision,
Logistics in manufacturing.
Logistics
Logistics in in manufacturing.
manufacturing. 

 and it presents the most recent trends, whereas Section 4
1. INTRODUCTION and it presents the most recent trends, whereas Section 4
1. INTRODUCTION and
and it it presents
describe the
the most
the technology
presents recent
recent trends,
mostinnovation of the
trends, whereas
fourth Section
whereas industrial4
1.
1. INTRODUCTION
INTRODUCTION describe the technology innovation of the fourth Section
industrial4
A century later from the introduction of the first assembly describe describe
revolution. the
the technology
Based on
technology innovation
these analysis,
innovation of the
Section
of the fourth
5
fourth industrial
assesses the
industrial
A century later from the introduction of the first assembly revolution. revolution.
impact that
Based on these analysis, Section 5 assesses
Based
I40 has on
on these
modern analysis,
ASs in Section
term of 5
novelassesses
assembly
the
the
A
linecentury later
later from
in Highland Parkthe introduction
Ford Plant inof the
the first
Michigan first assembly
both the revolution. Based hason on these analysis, Section 5 assesses the
A
linecentury
in Highland fromParktheFord introduction
Plant inofMichigan both the impact
assembly
impact
line
that I40
that I40
configurations,has on
modern
modern
innovative
ASs in term
ASs in term
technologies
of novel
of novel
assembly
assembly
and new
line in
industrial Highland
technologies
line in Highland Park
Park and Ford
and
Ford thethePlant
Plant in
market Michigan
demand
in Michigan both the
radically impact that I40 has on modern
the line configurations, innovative technologies and newASs in term of novel assembly
industrial technologies market demand both radically
industrial
changed. technologies
industrial Breakthroughand the
the market
market demand
innovations as the radically global line line configurations,
management principles innovative
configurations,
management
proposing the
principles innovative
proposing the
technologies
main characteristics
technologies
main characteristics
and
and newnewof
of
changed. technologies
Breakthroughand innovations demand
as the radically global AS40. managementFinally, principles
conclusions proposing
and the
further main
research characteristics
opportunities of
changed.
communication
changed. Breakthrough
network,
Breakthrough e.g.innovations
Internet,
innovations andas
as the
the global
interconnected
global management
AS40. Finally, principles
conclusions proposing
and the
further main
research characteristics
opportunities of
communication network, e.g. Internet, and interconnected AS40. are Finally,
drawn in conclusions
Section 6. and further research opportunities
communication
intelligent
communication sensors network,
are
network, e.g.
enabling
e.g. Internet,
technologies
Internet, and
and interconnected
for production
interconnected AS40.
are Finally,
drawn in conclusions
Section 6. and further research opportunities
intelligent sensors are enabling technologies for production are drawn in Section 6.
intelligent
systems.
intelligent sensors
sensors are
Similarly, the enabling
are market demand technologies
rapidlyfor production
evolved over are drawn in Section 6.
systems. Similarly, the enabling
market demand technologies
rapidlyfor production
evolved over 2. ASSEMBLY SYSTEM DESIGN
systems.
the last
systems. Similarly,
decades the market
requiring demand
high rapidly
volumes evolved
of over
products 2. ASSEMBLY SYSTEM DESIGN
the last Similarly,
decades the market demand
requiring high volumesrapidly evolved of products over 2.
2. ASSEMBLY
ASSEMBLY SYSTEM
SYSTEMdecisions DESIGN
DESIGNwhose aim is
the last
individually decades
the last decades requiring
personalized
requiring high
considering volumes
high volumesthe singleof products
customer
products AS design is aa process
of customer AS design is of interrelated
individually personalized considering the single process of interrelated decisions whose aim is
individually
individually personalized
requirements, introducing the considering
concept ofthe mass single customer
customization.
customer AS design
requirements, personalized
introducing the considering
concept ofthe mass single
customization. AS
to designaais
to define
define
aa process
isproper
process
proper
of
of interrelated
configuration
interrelated
configuration
and decisions
and
efficient whose
decisions
efficient whose aim
aim is
management
management is
requirements,
These trends
requirements, introducing
determined
introducingathe athe concept
disruptive
concept leap of
leap mass
of mass for customization.
manufacturing to define
strategies a proper
for a configuration
production and
system efficient
which management
assemblies
These trends determined disruptive for customization.
manufacturing to define a proper configuration and efficient management
These
processestrends determined
resulting in aaa disruptive
disruptive
remarkably leaphigher production strategies
for manufacturing
manufacturing for a production system which assemblies
These
processestrends determined
resulting in a remarkably leap for
higher production strategiescomponentsfor
strategies
componentsfor
into aaa final
into a final
production
product. system
production Several are
product. system
Several are
which
which assemblies
the dimensions
assemblies
the dimensions
processes
efficiency,
processes resulting
product
resulting in
quality
in a
a remarkably
and customer
remarkably higher
higher production
satisfaction. This
production components
to consider ininto
AS a final
design. product. Several are the dimensions
efficiency, product quality and customer satisfaction. This to components
consider ininto
AS adesign.
final product. Several are the dimensions
efficiency,
recent product
revolution
productof quality and
and customer
the industrial satisfaction.
environment This
is named
This to consider in AS
efficiency,
recent revolution ofquality
the industrial customer satisfaction.
environment is named to consider is
Balancing AS design.
in certainlydesign.the most investigated one. Since the
recent
“Industry
recent revolution
4.0”
revolution (I40)of
of the
the industrial
(Kagermann
industrial et environment
al., 2013).
environment is
is named
Traditional
named Balancing is certainly the most investigated one. Since the
“Industry 4.0” (I40) (Kagermann et al., 2013). Traditional Balancing is certainly the
assembly
“Industry lines
4.0”
“Industry lines
assembly
descended
(I40) (Kagermann
(I40) (Kagermann
4.0” descended from the
from the et
et
Ford
Ford
al., 2013).
model
al.,model T Traditional
one
2013).T Traditional are no
one are no Balancing
first mathematical
is certainly
first mathematical the most
formulation
formulationmostof investigated
ALB by Salveson
ofinvestigated
ALB by Salveson
one.
one. Since
Since the
(1955),
the
(1955),
assembly
longer
assembly lines
suitable descended
for
lines descended today from the
industrial Ford model
environment. T one Aare
newno first
first mathematical
researchers and
mathematical formulation
practitioners
formulation of
of ALB
developed
ALB by
by Salveson
several models
Salveson (1955),
and
(1955),
longer suitable for todayfrom the Ford
industrial model T oneAarenew
environment. no researchers and practitioners developed several models and
longer
generationsuitable for
for today
of assembly systems industrial
(ASs) environment.
is sought to seize A
A newthe researchers
methods to assignand
and practitioners
assembly tasks developed several
several models
to workstations and
to optimize
longer
generationsuitable
of assembly today systems industrial
(ASs) environment.
is sought to seize the aresearchers
new methods to assign
methods
certain to assign
objective
practitioners
assembly tasks
assembly
function
developed
tasks
and to
to workstations
to workstations
satisfy a set of
models
to
and
to optimize
optimize
constraints.
generation
opportunities
generation of assembly
that
of that the
assembly systems
fourth
systems (ASs)
industrial is sought
revolution
(ASs)revolution
is sought offers. to seize
offers. the methods to assign assembly tasks to
to seize the a certain objective function and to satisfy a set of constraints.workstations to optimize
opportunities the fourth industrial aa certain
opportunities
opportunities that
that the
the fourth
fourth industrial
industrial revolution
revolution offers.
offers. certain objective
Traditional objective
objective function
function and
functions
anddealto
to satisfy
with the
satisfy aa set
set of
of constraints.
minimization
constraints.of
This paper presents the first original framework which Traditional Traditional
the workstation
objective
objective station
functions
functions
number
deal
dealor
with the
with
the the
assembly
minimization
minimization
line
of
of
cycle
This paper presents the first original framework which Traditional the workstation objective stationfunctions
numberdeal or with the minimization
the assembly line cycleof
This
This paper
investigates
paper presents
the impact
presents the
that
the first
I40
first original
principles
original framework
have
framework on ASs. which
Aim
which the
time,workstation
whereas thestation number
constraints or
usually the assembly
ensure the line cycle
assembly
investigates the impact that I40 principles have on ASs. Aim the time,workstation
whereas thestation numberusually
constraints or the ensure
assembly the line cycle
assembly
investigates
of this paper the
the impact
is the that I40
I40 principles
improvement of have the on ASs.
ASs. Aim
design and time,
investigates
of this paper impact
is the that improvement principles of have the on design Aim time, whereas
and precedence
precedence
the
the constraints
whereasrelations
relations constraints usually
usually ensure
and represent
and represent
the assembly
ensure
the assembly
the
the assemblytask
assembly
task
of
of this
this paper
configuration
paper of is
is the
modern
the improvement
ASs
improvement to of
leverage
of the
the design
I40
design and
features
and precedence
attributes as relations
the time, and
cost or represent
space to the
perform assembly
them task
(Boysen
configuration of modern ASs to leverage I40 features attributes precedenceas the relations
time, andor represent
cost space to the assembly
perform them task
(Boysen
configuration
establishing
configurationthe ofheremodern
defined ASs to
to leverage
“Assembly System I40 features
4.0” (AS40).
features et attributes as
al., 2007). the time, cost or space to perform them (Boysen
establishing theofheremodern
defined ASs “Assembly leverage
System I40 4.0” (AS40). attributes
et al., as
2007). the time, cost or space to perform them (Boysen
The manuscript
establishing the is organized
the here defined
defined “Assemblyas follows.System Section 4.0”2 presents
(AS40).
(AS40). et al.,
establishing
The manuscript here
is organized “Assembly
as follows.System Section 4.0”2 presents et al., 2007).
2007). is the short-term counterpart of the ALB
Sequencing
The
the manuscript
traditional
The traditional is organized
dimensions
manuscriptdimensions
is organized of as
AS follows.
design Section
and it 2 presents
analyses the
the of asASfollows.
design and Section 2 presents
it analyses Sequencing is the short-term counterpart of the ALB
the Sequencing Thisis problem
the
the
the traditional
related
traditional
related
dimensions
dimensions of
AS configurations.
AS configurations. of AS design
design33and
Section
AS
Section
it
it analyses
andinvestigates
analyses the
investigates the
problem.
Sequencing
the problem. the short-term
Thisis problem
arises in counterpart
short-term mixed-modeloflines
arises in counterpart
mixed-modeloflines
the ALB
which
the which
ALB
related
evolution AS
of theconfigurations.
industrial environment Section 33in theinvestigates
last centuries the problem.
assembly
problem. This
several
This problem
product
problem arises
models
arises in
in mixed-model
from
mixed-modela common lines
lines which
product
which
related AS configurations. Section
evolution of the industrial environment in the last centuries assemblyinvestigates the assembly several product models from a common product
evolution several product models from a common product
evolution of of the
the industrial
industrial environment
environment in in the
the last
last centuries
centuries assembly several product models from a common product
2405-8963 © 2017, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved.
Copyright © 2017 IFAC 5880
Peer review©under
Copyright 2017 responsibility
IFAC of International Federation of Automatic
5880Control.
Copyright © 2017 IFAC
10.1016/j.ifacol.2017.08.1121
Copyright © 2017 IFAC 5880
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Proceedings of the 20th IFAC World Congress
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family to fulfil the requirements of mass customization. In Finally, recent advances in the literature suggest to include
these ASs, tasks of different models are performed in the the ergonomic risk into AS design. Assembly workers are
same workstation during consecutive cycles. Aim of the intrinsically prone to musculoskeletal disorders, due to
assembly line sequencing is to define an intermixed sequence strenuous operations repeated at high frequency. Ergonomic
of product models such that the customer demand of all risk at AS has a negative impact both on worker health and
models is satisfied minimizing the sequence dependent work life quality as well on company economic results and
overload. Work overloads occur if several work intensive reputation. The latest developments in legislations (EU
models follow each other at the same workstation. These Machinery directive, 2006/42/EC, 89/391/EEC, Occupational
overloads could result in the entire assembly line stop, the Safety and Health act) and the workforce aging in the
support of utility workers to the critical workstations or developed countries force to include the ergonomic aspect
unfinished tasks to be completed off-line (Boysen et al., into AS design (Otto and Scholl, 2011). The following Fig. 1
2009). summarizes the aforedescribed dimensions of AS design.
The assembly of different product models in the same Balancing Ergonomic risk
workstation requires to properly manage the feeding of • Impact on workers &
• Station number
several components. This relevant dimension of AS design is • Cycle time companies
known as material feeding (or part logistic). Its aim is to feed • Precedence graph • Legislation
• Task attributes • Aging workforce
the AS with the right type and quantity of components at the • Musculoskeletal disorders
right location and time. Two are the most relevant material
feeding decisions, the material storage and the feeding policy. Sequencing Material feeding
The former defines the packaging type and dimensions to • Mixed-model AS • Material storage
store the components along the AS (Bortolini et al., 2016). • Work overload • Feeding policy
Considering the latter decision that deals with material
feeding, three are the possible feeding policies to adopt Equipment selection Learning effect
(Faccio et al., 2015). Line side stocking suggests to store each • Total profitability • Learning stage
component in individual containers, transport them from the • Flexibility • Task shift
warehouse to the workstations and replace them when empty.
Kitting feeding uses identified areas to group in one container Fig. 1. Dimensions of assembly system design
specific components and subassemblies which together
support the assembly tasks of a particular product model. 3. INDUSTRIAL ENVIRONMENT EVOLUTION
Finally, kanban feeding policy stores each component type in
proper bins to which are attached kanbans. The containers are AS design has to consider the industrial environment in
formed in a supermarket area whereas they are stored in which the production system operates. Indeed, the industrial
defined quantities at station level. When the components in a environment discontinuously evolved over the centuries.
container are depleted, the related kanban is released and the Discontinuities are identified by disruptive leaps in
material replenishment occurs. manufacturing processes resulting in remarkably higher
productivity. These discontinuities result in four industrial
A further dimension of AS design is the equipment selection. revolutions. The first revolution occurred from late 18th to
Certain tasks could require specific piece of equipment to be mid 19th century. The technology innovations which enabled
performed, whereas others could benefit from the adoption of a significant productivity leap were the steam power and
automation to reduce their duration. Purpose of the machine tools. These technologies allow to manufacture few
equipment selection is the definition of which pieces of complex and expensive products customized on the end-user
equipment to purchase and install in which workstations to needs. This production paradigm is named “craft production”
optimize a set of AS key performance indices (KPIs) (Koren, 2010). The second industrial revolution took place
(Bukchin and Tzur, 2000). from late 19th to mid 20th century and involved the
introduction of electricity in manufacturing processes. This
Learning effect is a relevant dimension to design ASs. It enabled to produce large volume of identical products at low
refers to the inversely proportional relationship between the unitary cost introducing the concept of “mass production”
task duration and the number of task repetitions done by a (Langlois and Robertson, 1989). During this period, the ASs
worker (Cohen et al., 2008). This effect is particularly were introduced and adopted for the first time in the history.
relevant for ASs operating in today industrial environment. The mass production paradigm is overcome during the third
The mass-customization and the reduced life cycle of industrial revolution (from late 20th to early 21st century) with
products determine the frequent launch of high-personalized the introduction of electronic, information technology (IT)
new goods. The introduction of a new product in an AS is and automation. These technologies enabled to develop a
distinguished by an initial period, called learning stage, novel production paradigm to face the customer demand of a
characterized by a limited productivity due to worker training greater product variety at competitive costs and in large
of new assembly activities. Shortened learning stage results quantities, namely “mass customization” (Misthal et. al,
in increased product sales in the life cycle phase 2016). Finally, the industrial environment is nowadays
distinguished by the highest revenues, which is the time a experiencing its fourth industrial revolution, called I40. The
new product reaches the market. ubiquitous use of cheap sensors and actuators communicating
through a network, e.g. Internet, enables the real-time

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Proceedings of the 20th IFAC World Congress
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Toulouse, France, July 9-14, 2017 Marco Bortolini et al. / IFAC PapersOnLine 50-1 (2017) 5700–5705

connection between systems, machines, tools, workers, countries developed national policies to financially support
customers, products and other objects defining the so-called I40 related initiatives. In Germany, “Industrie 4.0” platform
Internet of things (IoT) (Stankovic, 2014). The enormous launched in 2010 aims at founding with € 1 billion private
quantity of data generated by these connect objects represent projects and applied research centres as well to provide tax
the raw material of 21st century. IoT allows to develop a benefits for investments in technological start-ups
novel production paradigm, called personalized production. (Kagermann et al., 2013). United Kingdom invested £ 0.8
This paradigm fulfils the customer ongoing desire to billion to develop high-value manufacturing centres, called
participate to the product design phase. The following Table “Catapult centres”, to support companies to access research
1 presents the period, technology innovation and production and expertise in specific manufacturing areas (Silva and
paradigm of the analysed industrial revolutions. Andersen, 2015). France recently presented its “Industrie du
Futur” initiative which funds with €10 billion subsidized
Table 1. Period, technology innovation and production loans for small and medium enterprises (SMEs) to foster the
paradigm of the four industrial revolutions. country re-industrialization adopting cutting edge digital
1st industrial 2nd industrial 3rd industrial 4th industrial technologies (Gouvernement de la République Française,
revolution revolution revolution revolution 2015). In 2016, Italy allocated €13 billion for the “Piano
nazionale Industria 4.0” plan to promote R&D activities and
private investments, through fiscal benefits, in I40 enabling
technologies (Governo della Repubblica Italiana, 2016).
Period 1780-1860 1870-1950 1970-2000 2000 - Furthermore, at European level Horizon 2020 (H2020)
steam power Internet research program finances demonstration projects aimed at
Technology electronic, IT,
innovation
& machine electricity
automation
connected developing smart, digital, human-centred and customer-
tools sensors
focused manufacturing solutions. Finally, outside Europe,
Production craft mass mass personalized “Manufacturing USA” program invests $ 0.5 billion to create
paradigm production production customization production
a network of American institutes for manufacturing
Furthermore, today industrial environment is characterized by innovation to scale-up at national level advanced
three mega-trends. First, the workforce is alarmingly aging. technologies and processes leveraging industrial, academic
In the last 15 years the percentage of European employees and governmental resources and expertise (Executive Office
older than 50 years rose from 21.6% to 30.4% (OECD, of the President, 2016).
2015). 5.9 million people of today European workforce are Purpose of all the aforementioned public initiatives is the
older than 60 years (7.4% of the total workforce). Second, development of a new generation of smart factories grounded
western countries, and Europe in particular, are currently on the manufacturing process digitalization. Smart factories
experiencing the re-shoring of production facilities of I40 era are distinguished by an increased production
previously off-shored to emerging countries (Ellram et al., flexibility thought the use of real-time reconfigurable
2013). This mega-trend is determined by an increased labour machines that allow the personalized production of products
cost in emerging countries which made it comparable to the in batches as small as the unique item. The trend of
western one, the higher soft and digital skills of western manufacturing process digitalization which characterizes I40
workers compared to the emerging country competitors, the is based on the enabling technologies analysed in the
achievable savings in transportation expenditure that following.
distinguish local supply chains and the flexibility and
responsiveness required to target nowadays customer demand Internet of Things (IoT) is “a world-wide network of
(Davies, 2015). Finally, efficient and distributed interconnected objects uniquely addressable, based on
communication networks are a common features of western standard communication protocols” (Atzori, 2010). This
countries. In Europe, for instance, Internet penetration definition suggests the ubiquitous presence, even in the
increased from 55% to 81% in the last 9 years and the industrial environment, of several things or objects able to
adoption of broadband connections shows a similar pattern cooperate and interact with each other for a common purpose.
(Eurostat, 2016). Considering the evolution of the industrial
environment and the current mega-trends, the next Section 4 Interconnected heterogeneous objects generate a huge
analyses the fourth industrial revolution, its enabling amount of data of different types at high pace. These
technologies and the government policies which support it. enormous datasets are defined Big Data. Their most relevant
features are proposed by Gantz and Reinsel (2011) using the
4. INDUSTRY 4.0 4Vs model. Volume represents the generation and storage of
huge data quantities, Velocity stands for the rapid generation
The term I40 has been proposed for the first time in 2010 by of data and the required timely analysis, whereas Variety
the German government as part of the “High-Tech Strategy indicates the various types of structured and unstructured data
2020 Action Plan” to identify the fourth industrial revolution gathered from different sources. Value is the most important
(Kagermann et al., 2013). I40 can be defined as the V and it refers to the great hidden value stored in these
comprehensive transformation of the entire industrial datasets which should be explored and mined through novel
production through the merging of Internet and information methods and techniques.
& communication technologies (ICT) with traditional
manufacturing processes (Davies, 2015). Several European Considering the rapid generation of data and the required
timely analysis, real-time decision systems are of major

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interest for I40. Operation research can contribute with the Finally, additive manufacturing is the process of making
development of appropriate real-time optimization models objects from 3D models adding proper material layer upon
and methods. Powerful and versatile metaheuristics, as layer. This technology minimizes the raw material waste and
simulated annealing, tabu search and genetic algorithms can it is able to fabricate complex shapes without fixtures and
be adopted for real-time decision making (Séguin et al., cutting tools. Furthermore, additive manufacturing fosters the
1997). on-demand production of personalized goods promoting the
distributed and flexible manufacturing approaches as well as
New computing model called cloud computing are used to build-to-order strategies (Huang et al., 2013). The following
store and analyse the enormous datasets typical of I40 Fig. 2 presents the aforedescribed enabling technologies of
applications. In cloud computing, the resources are provided I40.
as general utilities that are on-demand leased and released by
users through Internet. Computing and storage capacity is Cloud computing
Big Data
shared by partitioning the physical resources using
Real-time
virtualization technologies (Zhang et al., 2010). optimization

Internet of Things Cyber Physical System


The networked systems sensorized to acquire real-time data
from the field require a proper architecture, named Cyber
Physical System (CPS), to manage the interconnection Enabling technologies
between their physical assets and computational capabilities. of Industry 4.0
Smart sensors acquire accurate and reliable data from several
Machine learning
devices. Then, these data are transformed into meaningful
Cobot
information which are collected in a central hub. Specific Additive manufacturing

analytics are implemented to generate thorough knowledge of Augmented reality


the monitored system to support the decision process of
expert users (Lee et al., 2015).
Fig. 2. Enabling technologies of Industry 4.0
Preventive decisions and self-configurable devices benefit
from the adoption of machine learning. These cluster of 5. ASSEMBLY SYSTEM 4.0
computer algorithms original of the artificial intelligence
field are designed to autonomously learn and execute tasks. The adoption of I40 enabling technologies in production
The learning process is typically based on historic data used systems has a disruptive impact and improves the factory
in a training phase. Based on these examples, machine technical, economic and social performances. In particular,
learning algorithms predict future values that assist the integration of these technologies in the design and
autonomous decision processes (Flach, 2012). management of assembly processes leads to the here defined
AS40, the novel generation of ASs. The application of the
Following the deeply analysed software perspective, three are IoT technology to assembly processes is the keystone of
the main enabling hardware technologies for I40. Cobots, AS40. Every workstation, storage location, piece of
namely collaborative robots, represent a new generation of equipment, product, worker and generic entity of the AS is
industrial robots which actively cooperate with human sensorized to communicate in real-time specific data. An
operators during working activities. Interaction between assembly control system (ACS) leverages these data to
human and robot depends on the support required by the implement proper models and methods to automatically
worker. In workplace sharing system, human and robot manage and configure the AS. This AS architecture eases the
operate in the same workplace with limited interaction. In development of different applications which define the main
workplace and time sharing systems, human and robot are characteristics of AS40.
able to jointly perform working activities. The robot is used
as an intelligent and powerful tool by the human operator. Aided assembly improve the fastening and picking activities
Despite the great advantages of this technology for human through several technologies reducing their duration and
health, e.g. aided load handling, current EU regulation ensuring safe working conditions. As soon as a product
considers that the robot installation within reach of human reaches a workstation, assisted picking devices, as light
operator does not comply with safety conditions (DIN EN picking, automatically show the components to pick from the
775). However, recently proposed international standards workstation storage locations considering the final product to
(ISO 10218) aim to provide regulations for human-robot assembly and the optimal picking sequence that minimizes
interaction. the worker effort. During fastening activities, the worker is
aided through augmented realty devices, as head-worn
The second enabling hardware technology for I40 is displays, which suggest the sequence of activities to complete
augmented reality. This technology improves the real an assembly task considering the customer personalization. A
surrounding environment of a human with virtual, e.g. further I40 technology assists the workers during assembly
computer created, objects that coexist in the same space of activities. Cobots automatically adjust their configuration in
the real environment. Augmented reality operates in real-time real-time to best fit with the worker physique and the
in the human environment and it allows people to interact fastening task features. Moreover, cobots provide to the
both with real and with virtual objects which are aligned and worker an artificial force to perform hazardous activities
referred with each other (Azuma et al., 2001). reducing the ergonomic risk of strenuous tasks.

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Concerning material feeding, intelligent storage management using these data. For instance, assembly line self-scheduling
system ensures significant economic savings. Sensorized and self-balancing define in real-time the optimal product
workstation storage locations self-monitor their inventory sequence and task assignment considering the skills of the
level and automatically send refilling requests to the central available workers, the inventory level of the different
warehouse. Thus, unexpected consumption rates do not result components and the availability of the installed pieces of
in stock-outs due to these system resilience. Intelligent equipment. Indeed, the ACS leverages the big data that
storage management system is connected with the purchasing represent the AS evolution over time to automatically re-
department to communicate the obsolete components of the configure the AS. Finally, the data collected from different
assembly process avoiding unnecessary orders. Finally, ASs are shared through cloud computing between factories to
component inventory level is kept as low as possible using provide the company decision support system with updated,
the real-time information provided by the customer orders reliable and meaningful information. The following Fig. 3
through the ACS. summarizes the main characteristics of AS40.
A further characteristic of AS40 deals with the workstation
configuration. Self-configured workstation layout
autonomously adjust the rack, shelf and workbench
dimensions considering the assembly product and the
assigned worker. Sensors and actuators are embedded in the
workstation structure which automatically adjust the shelves
width and depth as well as the workbench height. These
regulations consider the assembly product shape, weight and
dimensions as well as the assigned worker physique. Self-
configured workstation layout aims to optimize the assembly
activities minimizing the picking and fastening time and
ensuring ergonomic working conditions.
Sensorized and connected AS entities ensure a complete
product and process traceability. Every assembly task is
monitored to detect in real-time any possible error or non-
compliance. Product quality is tremendously improved
replacing statistical fault analysis with single item control.
Worker activity is continuously monitored to track the
assembled components and the task duration. Pieces of Fig. 3. Main characteristics of assembly system 4.0.
equipment are properly sensorized to control their reliability
and failures. The ACS collects all these valuable data and 6. CONCLUSIONS
store them in the company cloud database for a later use. The
implementation of the aforedescribed CPS guarantees a This paper presents an original framework which investigates
complete product traceability during the entire assembly the impact that the fourth industrial revolution has on AS
process. design and management. AS design is a process of
interrelated decisions whose aim is to define a proper
Late customization of assembled products is one of the most configuration and efficient management strategies for these
relevant features of AS40. Accordingly to the personalized systems. Beyond assembly line balancing and scheduling,
production paradigm, the customer is involved since the several are the relevant dimensions of this process, as
design phase to tailor the product on its own needs. However, material feeding, equipment selection, ergonomic risk and
customer involvement is not limited to this phase. Late learning effect. Furthermore, AS design has to consider the
modifications of product specifications are allowed industrial environment in which the system operates. Four
exploiting the company cloud database. The customer can industrial revolutions have taken place in the last 3 centuries.
monitor the assembly process and confirm at predetermined Each revolution is distinguished by a bunch of technology
stages the configurations of the personalized product he/she innovations which enable a significant productivity leap and
designed. AS40 are equipped with 3D printers and other a novel production paradigm. The industrial revolution of the
additive manufacturing machines to ensure the required 21st century exploits ubiquitous sensors and actuators which
flexibility to the assembly process. These pieces of communicate through Internet to connect in real-time
equipment manufacture personalized components using the machines, tools, workers, customers and products. The
computerized solid models provided by the customers. achieved flexibility and responsiveness enables to involve the
customers since the product design phase defining the
Finally, the enormous quantity of data collected from the personalized production paradigm. The German government
assembly field represents the AS40 value-added from the coined the term I40 to identify the comprehensive
company perspective. However, these unstructured data transformation of the entire industrial production through the
gathered from different sources have to be transformed in merging of Internet and ICT technologies with traditional
meaningful information. Assembly control system (ACS) manufacturing processes which distinguishes the fourth
implement real-time optimization models and machine industrial revolution. The trend of manufacturing process
learning algorithms to automatically configure the AS40

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digitalization is based on a set of enabling technologies Eurostat (2016). Digital economy and society statistics -
presented in this paper, namely IoT, big data, real-time households and individuals. Retrieved from
optimization, cloud computing, CPS, additive manufacturing, http://ec.europa.eu/eurostat/statistics-
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integration of these technologies in the design and stics_-_households_and_individuals.
management of ASs leads to the here defined generation of Executive Office of the President (2016). National network
AS40. Six are the main characteristics of AS 40, namely for manufacturing innovation program. Strategic plan.
aided assembly, intelligent storage management, self- Retrieved from https://www.manufacturing.gov/2015-
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Packaging strategy definition for sales kits within an
Further research should support the proposed framework assembly system. International Journal of Production
presenting case studies of real production systems which Research, 53(11), 3288–3305.
already implemented portions of the presented architecture Flach, P. (2012). Machine learning: the art and science of
for the design and management of ASs. Moreover, focused algorithms that make sense of data. Cambridge
research activities are strongly encouraged to deeply University Press.
investigate the adoption of a specific I40 enabling technology Gantz, J., and Reinsel, D. (2011). Extracting value from
in the AS domain. Beyond theoretical studies, the chaos. IDC iview, Framingham.
development of hardware solutions and experimental tests are Gouvernement de la République Française (2015). Industry
widely sought to validate the research results and ensure their of the Future. Retrieved from
diffusion and adoption by industrial partners. http://www.economie.gouv.fr/lancement-seconde-phase-
nouvelle-france-industrielle.
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