Development of Innovative Operational Flexibility Measurement Model for Smart Systems in Industry 4.0 Paradigm

The exponential growth of cutting-edge technologies continuously pushing the manufacturing industry into the paradigm of smart manufacturing. Smart manufacturing provides the pace of highly competitive market demand and customized intensive production. The goal of smart manufacturing technologies embedded systems in the Industry 4.0 paradigm and lean production is to enhance the flexibility in all tears of the enterprise. It is a big challenge, to measure the flexibility of smart systems for decision-making and adaptation of the new manufacturing technologies. The conceptual architecture of smart manufacturing systems has been proposed to solve the problem. Operational flexibility has been measured using a mathematical model for smart manufacturing in the Open Platform Communication Unified Architecture enabled Cyber-Physical Production System at shop floor level and validated. The results obtained from experimentation depict the operational flexibility, maximum capacity, and breakeven point of the manufacturing system have been improved by using smart manufacturing technologies. The proposed model improves the product manufacturing using Smart Computer Numeric Control Machining, Smart Autonomous Robotic Machining, Smart Additive Manufacturing and Smart Hybrid Additive & Subtractive Manufacturing up to 30.4%, 53.6%, 55% and 65% respectively. It will also help the decision-makers to overcome the challenges of transformation from conventional to smart manufacturing industry 4.0 paradigm.