The concept of digital twinning is essential for smart manufacturing and cyber-physical systems to be connected to the Metaverse. These digital representations of physical objects can be used for real-time analysis, simulations, and predictive maintenance. A combination of smart manufacturing, Industry 4.0, and the Metaverse can lead to sustainable productivity in industries. This paper presents a practical approach to implementing digital twins of a magnetic forging holder that was designed and manufactured in this project. Thus, this paper makes two important contributions: the first contribution is the manufacturing of the holder, and the second significant contribution is the creation of its digital twin. The holder benefits from a special design and implementation, making it a user-friendly and powerful tool in materials research. More specifically, it can be employed for the thermomechanical influencing of the structure and, hence, the final properties of the materials under deve... [more]

The expansion of end-to-end Industry 4.0 technologies in various industries has caused a technological shock in the mineral resource sector, wherein itsdigital maturity is lower than in the manufacturing sector. As a result of the shock, the productivity and profitability of raw materials extraction has begun to lag behind the industries of its deep processing, which, in the conditions of volatile raw materials markets, can provoke sectoral crises. The diffusion of Industry 4.0 technologies in the mining sector (Mining 4.0) can prevent a technological shock if they are implemented in all segments, including quarrying (Surface Mining 4.0). The Surface Mining 4.0 technological platform would connect the advanced achievements of the Fourth Industrial Revolution (end-to-end digital artificial intelligence technologies, cyber-physical systems and unmanned production with traditional geotechnology) without canceling them, but instead bringing them to a new level of productivity, resource con... [more]

With the arrival of Industry 4.0, interoperability has become a major subject for companies worldwide. It is a crucial asset that enables new technologies and possibilities (Industrial Internet of Things, predictive maintenance or traceability solutions). With the increasing importance of data in business use cases, companies are faced with a choice between two interoperability approaches to deal with the challenge of reconciling different domains: standardization and mediation. This paper presents an analysis of each approach and proposes a decision-making methodology based on the Analytic Hierarchy Process (AHP) that aims to help companies in choosing the most suitable solution to resolve interoperability challenges.

In enterprises, the management of detection methods usually refers to ensuring the identification of nonconformities. This management is incomplete and incompatible with the concept of sustainability (it ignores electricity consumption and costs). To date, no models have been developed to support the analysis of detection methods in terms of the relationship of efficiency−energy consumption. The purpose of the study was to develop proprietary software to analyse the level of efficiency of detection methods for casting products in the context of their energy intensity. The model supports effective management of the quality control process, optimising the relationship of product quality−energy intensity of the process. The model integrally combines detection methods, so it was possible to identify critical product nonconformities and analyse these methods to determine their effectiveness, time efficiency, cost efficiency, and energy intensity. As a result of the implications of the softw... [more]

Mining of minerals is an important part of the technical sciences, for which the certainty and unambiguity of terms and the correct application of definitions is an absolute requirement. At the same time, the expansion of Industry 4.0 technologies, both in practice and in scientific discussions, brings new terms to mining that are far from the original meaning. These terms include Data Mining and Mining 4.0, which, having a common digital core, refer to fundamentally different areas of human activity, and have the opposite meaning in relation to the use of resources (digital ones—endless, and the natural ones—finite). The indiscriminate use of the term “mining” is especially dangerous in the context of Mining 4.0, in which digital technologies allow the intensification of the exploitation of natural resources. This brief Perspective paper will show the role of terminology in Mining 4.0 and offer an interpretation of its relationship with Data Mining.

Human factor plays an important role in the implementation of the fourth industrial revolution (Industry 4.0). The concept of Industry 4.0 is poorly researched, particularly the social aspect. The authors have conducted a study to determine the level of preparation of employees for the introduction of technological changes. This study involved conducting a survey on a sample of 453 employees based in four organizations within the automotive industry. The respondents were thereafter divided into groups based on age and positions held. The employees’ knowledge of the Industry 4.0 technology was examined, and their openness to change and readiness to increase competence was determined. A causal relationship was found between knowledge and trust in technology. Employees’ fears associated with production automation were discussed. A group of production workers was found to be the least prepared to implement technology changes. Actions to improve the situation and potential consequences of i... [more]

I4.0 promotes a future in which highly individualized goods are mass produced at a competitive price through autonomous, responsive manufacturing. In order to attain market competitiveness, organizations require proper integration of I4.0 technologies and manufacturing strategy outputs (MSOs). Implementing such a comprehensive integration relies on carefully selecting I4.0 technologies to meet industrial requirements. There is little clarity on the impact of I4.0 technologies on MSOs, and the literature provides little attention to this topic. This research investigates the influence of I4.0 technologies on MSOs by combining reliable MCDM methods. This research uses a combination of fuzzy DEMATEL and fuzzy TOPSIS to evaluate the impact of I4.0 technologies on MSOs. The fuzzy theory is implemented in DEMATEL and TOPSIS to deal with the uncertainty and vagueness of human judgment. The FDEMATEL was utilized to identify interrelationships and determine criterion a’s weights, while the fuzz... [more]

Machine Learning (ML) is one of the major driving forces behind the fourth industrial revolution. This study reviews the ML applications in the life cycle stages of biofuels, i.e., soil, feedstock, production, consumption, and emissions. ML applications in the soil stage were mostly used for satellite images of land to estimate the yield of biofuels or a suitability analysis of agricultural land. The existing literature have reported on the assessment of rheological properties of the feedstocks and their effect on the quality of biofuels. The ML applications in the production stage include estimation and optimization of quality, quantity, and process conditions. The fuel consumption and emissions stage include analysis of engine performance and estimation of emissions temperature and composition. This study identifies the following trends: the most dominant ML method, the stage of life cycle getting the most usage of ML, the type of data used for the development of the ML-based models,... [more]

Leadership competencies are of crucial importance in every organisation as to a large extent they determine its success. This is especially evident in the time of Industry 4.0. Given this fact, the aim of our paper is to examine the relationship between leadership competencies and 4.0 leadership effectiveness. The heat and power plants industry was chosen as the subject of our research. The fuzzy-set qualitative comparative analysis (fs/QCA) was used as the research method. It enabled us not only to analyse particular variables, competences, and typical statistical relations between them, but we also revealed the patterns of causal relationships between particular variables. The key finding of our research was the juxtaposition of leadership competencies that are indispensable for 4.0 leaders in the CHP plants. We also found out that managerial competencies were not sufficient, and they should be supported by intellectual or socio-emotional ones.

The publication presents a picture of modern steelworks that is evolving from steelworks 3.0 to steelworks 4.0. The paper was created on the basis of secondary sources of information (desk research). The entire publication concerns the emerging opportunities for the development of the steel producers to Industry 4.0 and the changes already implemented in the steel plants. The collected information shows the support environment for changes in the steel sector (EU programs), the levels of evolution of steel mills, along with the areas of change in the steel industry and implemented investment projects. The work consists of a theoretical part based on a literature review and a practical part based on case studies. The work ends with a discussion in which the staged and segmented nature of the changes introduced in the analyzed sector is emphasized. Based on the three case studies described in the paper, a comparative analysis was conducted between them. When we tried to compare methods us... [more]

Industry 4.0, a term invented by Wolfgang Wahlster in Germany, is celebrating its 10th anniversary in 2021. Still, the digitalization of the production environment is one of the hottest topics in the computer science departments at universities and companies. Optimization of production processes or redefinition of the production concepts is meaningful in light of the current industrial and research agendas. Both the mentioned optimization and redefinition are considered in numerous subtopics and technologies. One of the most significant topics in these areas is the newest findings and applications of artificial intelligence (AI)—machine learning (ML) and deep convolutional neural networks (DCNNs). The authors invented a method and device that supports the wiring assembly in the control cabinet production process, namely, the Wire Label Reader (WLR) industrial system. The implementation of this device was a big technical challenge. It required very advanced IT technologies, ML, image re... [more]

Industrial environments are heterogeneous systems that create challenges of interoperability limiting the development of systems capable of working collaboratively from the point of view of machines and software. Additionally, environmental issues related to manufacturing systems have emerged during the last decades, related to sustainability problems faced in the world. Thus, the proposed work aims to present an interoperable solution based on events to reduce the complexity of integration, while creating energetic profiles for the machines to allow the optimization of their energy consumption. A publish/subscribe-based architecture is proposed, where the instantiation is based on Apache Kafka. The proposed solution was implemented in two robotic cells in the automotive industry, constituted by different hardware, which allowed testing the integration of different components. The energy consumption data was then sent to a Postgres database where a graphical interface allowed the opera... [more]

Nowadays products are developed at a rapid pace, with shorter and shorter times between concept and go to market. With the advancement in technology, product designers and manufacturers can use new approaches to obtain information about their products and transform it into knowledge that they can use to improve the product. We developed the Poket Framework platform to facilitate the generation of product knowledge. In order to increase the reliability and safety in operation of electrical equipment, an evaluation is proposed, through tests and studies, using the original Poket Framework platform. Thus, several tests and studies were performed, which included testing and analyzing the correct integration in several use cases and remote data acquisition, and testing and analysis of the Poket Framework using literature established data sets of household appliances and electrical systems. Possible evolutions and Poket platform extensions are also considered.

Digital technologies enable companies to build cyber-physical systems (CPS) in Industry 4.0. In the increasingly popular concept of Industry 4.0, an important research topic is the application of digital technology in industry, and in particular in specific industry sectors. The aim of this paper is to present the tools used in the steel industry in Poland on its way to the full digitalisation that is needed for the development of Industry 4.0. The paper consists of two parts: a literature review and a practical analysis. The paper provides the background information about digitalisation using digital tools in the steel industry in Poland. The paper was prepared based on secondary information and statistical data. The object of the research is the Polish steel sector. This study assumes that digitalisation is the main area of innovation in the steel industry. The digitalisation determines the creation of new or modified products, processes, techniques and expansion of the company’s inf... [more]

The growth of the renewable energy industry is happening at a swift pace pushed, by the emergence of Industry 4.0. Smart technologies like artificial intelligence (AI), Big Data, the Internet of Things (IoT), Digital Twin (DT), etc. enable companies within the sector of renewable energies to drastically improve their operations. In this sectoral context, where upgraded sustainability standards also play a vital role, it is necessary to fulfil the human capital requirements of the imminent technological advances. This article aims to determine the current skills of the renewable energy industry workforce and to predict the upcoming skill requirements linked to a digital transition by creating a unified database that contains both types of skills. This will serve as a tool for renewable energy businesses, education centers, and policymakers to plan the training itinerary necessary to close the skills gap, as part of the sectoral strategy to achieve a competent future workforce.

The United Nations established 17 Sustainable Development Goals (SDGs), and the fulfillment of the 7th, defined as “Ensure access to affordable, reliable, sustainable, and modern energy for all”, requires energy industry transitions and digital transformations, which implies that diverse stakeholders need to move fast to allow the growth of more flexible power systems. This paper contains the case report that addresses the commercial digital transformation process developed at AES Colombia, through the implementation of a modern platform based on specialized applications that use Industry 4.0 tools. The Chivor hydropower project, a 1000-MW powerplant that covers 6% of Colombia’s demand, which is owned by AES Colombia and constitutes its primary asset, is first described. Then, a description of Colombia’s complex market (energy matrix, trading and dispatch mechanisms, and future projects) is presented. Then, the methodology followed for the digital transformation process using modern to... [more]

Operation and maintenance constitute a substantial share of the lifecycle expenditures of an offshore renewable energy farm. A noteworthy number of methods and techniques have been developed to provide decision-making support in strategic planning and asset management. Condition monitoring instrumentation is commonly used, especially in offshore wind farms, due to the benefits it provides in terms of fault identification and performance evaluation and improvement. Incorporating technology advancements, a shift towards automation and digitalisation is taking place in the offshore maintenance sector. This paper reviews the existing literature and novel approaches in the operation and maintenance planning and the condition monitoring of offshore renewable energy farms, with an emphasis on the offshore wind sector, discussing their benefits and limitations. The state-of-the-art in industrial condition-based maintenance is reviewed, together with deterioration models and fault diagnosis and... [more]

The beginning of the 21st century for the fuel and energy complexes of most countries is characterized as a period of active restructuring and a fundamental shift in developmental priorities. The basis of these changes is technological development. Industry 4.0 technologies have particular importance in achieving maximum optimization of production processes. In the same way, they are applicable in establishing effective interaction between the energy sector and other sectors of the economy. The authors outline an approach to assessing the country’s fuel and energy balance state through the selected properties: sustainability, accessibility, efficiency, adaptability and reliability. Hence, a model of the fuel and energy complex was created on the example of the Russian Federation, considering the country’s territorial and functional division. The methodology is based on scenario modeling of the influence level of external challenges in conjunction with the accompanying technological dev... [more]

Strategic and tactical factors come into play in shop competitiveness where, in addition to the products sold, other marketing mix variables must also be considered. There are also subjective factors, such as perceptions through the senses. This became even more important when, as a result of the COVID-19 crisis and the forced closure of certain establishments with physical sales, it was necessary to increase profitability and efficiency. The aim of this study was to determine the exact role of sensory marketing in shop efficiency and profitability, based on the guiding principles of technology, innovation, and respect for the environment. We conducted an exploratory and experimental study consisting of the creation of a sensory strategy through the adaptation of the Hulten, Broweus and Van Dijk model on a specific establishment in the current era of Industry 4.0. The results indicate an increase in sales as well as customer satisfaction and happiness after implementing the relevant st... [more]

The SARS-CoV-2 pandemic is spreading rapidly and threatening lives all over the globe. Due to the pandemic, economies all over the world are in deep distress due to disruption in work and operations across all sectors. The present case study was performed for a private Indian manufacturing company that has been affected to a great extent due to this pandemic, as India has the second highest number of SARS-CoV-2 cases after the USA. The deeply troubled company’s current predicament is very complex, as various factors are responsible for the crisis. In order to restore the company back to normal functioning, these factors were studied and evaluated. A diagnostic survey was conducted to obtain data about current working conditions of company. Data from the survey were analyzed qualitatively and quantitatively to identify and evaluate the disruptive factors. Based on this analysis, problems in operational activities were identified and appropriate improvement actions (best practices) were... [more]

In the 21st century, it is becoming increasingly clear that human activities and the activities of enterprises affect the environment. Therefore, it is important to learn about the methods in which companies minimize the negative effects of their activities. The article presents the steps taken and innovative actions carried out by enterprises in the energy sector. The article analyzes innovative activities undertaken and implemented by enterprises from the energy sector. The relationships between innovative strategies, including, inter alia, digitization, and Industry 4.0 solutions, in the development of companies and the achieved results concerning sustainable development and environmental impact. Digitization has far exceeded traditional productivity improvement ranges of 3−5% per year, with a clear cost improvement potential of well above 25%. Enterprises on a large scale make attempts to increase energy efficiency by implementing the state-of-the-art innovative technical and techn... [more]

Industry 4.0 is generalizing the use of wireless connectivity in manufacturing and logistics. Specifically, in Smart Logistics, novel Industry 4.0 technologies are used to enable agile supply chains, with reduced management, energy and storage costs. Cellular networks allow connectivity throughout all the scenarios where logistics processes take place, each having their own challenges. This paper explores such scenarios and challenges, and proposes 5G technology as a global unified connectivity solution. Moreover, this paper proposes a system for exploiting the application-specific optimization capabilities of 5G networks to better cater for the needs of Smart Logistics. An application traffic modeling process is proposed, along with a proactive approach to network optimization that can improve the Quality of Service and reduce connectivity costs.

Taking into account the impact of the COVID-19 and adopting the assessment optics of students from Generation Z currently entering the labor market, we have made the aim of this article to provide better insight into the relationship between Industry 4.0 and corporate social responsibility. The survey was conducted in the form of an online survey in two leading universities in Poland in the field of economic education. 646 students took part in the survey. The data were analyzed using logit regression models. The results of the study suggest that the increase in the use of management solutions supporting Industry 4.0 in the wake of the COVID-19 crisis will increase the importance of the economic, social, and environmental dimensions of corporate social responsibility. Pointing to the forecasted increase importance of corporate social responsibility, we suggest linking management solutions supporting Industry 4.0 with corporate social responsibility. However, we also draw attention to t... [more]

The Industry 4.0 Revolution that is taking place nowadays means that organizations face not only new opportunities, but also challenges related to the identification of their role in creating a modern smart world. The economies of many countries are under the significant and growing influence of various types of organizations, not only strong international business corporations, but also, more and more often, smaller but intelligent ones called smart organizations IR 4.0. Due to their unique characteristics, intelligent organizations are better able than others to cope with technological breakthroughs, social, and cultural problems as well as to compete effectively and develop in an environmentally sustainable way. With their growing potential, they are strengthening the economies of their countries of origin and daily operation. Their growing role is also visible in the processes of shaping competitiveness and achieving the sustainable development objectives of the European Union (EU)... [more]

Constructing the power curve of a power generation facility integrated with complex and large-scale industrial processes is a difficult task but can be accomplished using Industry 4.0 data analytics tools. This research attempts to construct the data-driven power curve of the generator installed at a 660 MW power plant by incorporating artificial intelligence (AI)-based modeling tools. The power produced from the generator is modeled by an artificial neural network (ANN)—a reliable data analytical technique of deep learning. Similarly, the R2.ai application, which belongs to the automated machine learning (AutoML) platform, is employed to show the alternative modeling methods in using the AI approach. Comparatively, the ANN performed well in the external validation test and was deployed to construct the generator’s power curve. Monte Carlo experiments comprising the power plant’s thermo-electric operating parameters and the Gaussian noise are simulated with the ANN, and thus the power... [more]