Agile in Green Smart Factories: A Methodology for Planning
Dr. Matevž Resman, doc. dr. Mihael Debevec, univ. dipl. inž., doc. dr. Marko Šimic, univ. dipl. inž., prof. dr. Niko Herakovič, univ. dipl. inž., vsi Univerza v Ljubljana, Fakulteta za strojništvo
Abstract:
Modern manufacturing is rapidly evolving, with agile and green companies shaping the future. These firms need new methodologies to streamline planning and navigate the complexities of Industry 4.0 technologies. The proposed methodology offers a step-by-step guide to transitioning from initial challenges to implementing smart factories with digital twins, enhancing competitiveness and fostering innovation.
This methodology involves identifying specific challenges and contexts, selecting appropriate models for a structured approach, and recognizing that digitalization requires a strategic mindset shift. Companies must understand the transformative potential of digital technologies, which can enhance efficiency, reduce costs, and improve productivity. Embracing technologies like IoT, AI, and data analytics is essential for fostering innovation and modernizing production processes.
The planning of smart factories consists of three key steps. The first step involves initial understanding workshops, which provide insights into current processes. Experts analyze systems and identify how Industry 4.0 technologies can be integrated, while also assessing the company’s readiness for transformation.
The second step focuses on developing the architectural model based on product differentiation. This simplifies material flow representation and increases transparency. Organizing the factory into levels improves management and monitoring.
The final step involves establishing a digital twin that communicates with the physical system in real time. This process includes classifying production systems, developing functional diagrams, creating digital models, enabling real-time data interaction, and providing visualization tools for stakeholders.
By following this structured methodology, companies can transition to smart factories, improving competitiveness and operational efficiency while fostering sustainable and innovative production systems.
Keywords:
methodology, agile factories, smart factories, green transformation, energy efficiency, social responsibility
Acknowledgement
The work was financially supported in the framework of the Slovenian Research and Innovation Agency – ARIS, Research Programme P2-0248 – Innovative manufacturing systems and processes, research project J2-4470 – Research on the reliability and efficiency of edge computing in a smart factory using 5G technologies. The work was funded by the European Union, project 101087348 – Strengthening the capacity for excellence of Slovenian and Croatian innovation ecosystems to support the digital and green transitions of maritime regions and project 101058693 – Sustainable Transition to the Agile and Green Enterprise (STAGE Project).