The evolution of world class manufacturing toward Industry 4.0: A case study in the automotive industry

Abstract

In order to increase the level of global competitiveness and improve the performance of production system, a large number of manufacturing companies have implemented world class manufacturing (WCM) approach, which has developed based on the third industrial revolution and the need for mass production. The evolution in production equipment and communication technologies, and the demand of markets for personalized mass production, have forced manufacturing companies to transform their production systems and prepare for a revolution. This revolution, known as Industry 4.0 (I4.0), or the digital transformation, has been introduced as a new type of organization of manufacturing systems that is more flexible and agile, and is based on using large amounts of information and data in the decision-making process. One of the main characteristics of this concept is decentralization, which allows different subsystems to make decisions autonomously in order to have self-organization systems. There are some important differences between the principles of WCM and I4.0. World class manufacturing is mainly based on continuous improvement and cost reduction, without a global vision for profit optimization. Industry 4.0 is mainly based on using all accessible information and data of systems and making decentralized decisions, but it also involves a global vision and a systemic approach to global profit optimization. However, achieving these objectives takes a very long time, and the challenges are numerous. As with all projects, for a transformation project to succeed, it is very important to define the transition phase and the way to change and introduce these new principles. This paper presents part of our research project, in collaboration with the Fiat Powertrain Technologies company, concerning the transformation of their production system toward the factory of the future. We highlight the design principles of I4.0 and the potential of the WCM system for transformation and achieving development of the characteristics of I4.0. We focus on five of the principal technical pillars of WCM and the steps in their development, and present some modifications in adoption of the design principles of I4.0. An example of change in the professional maintenance pillar of WCM is also presented.