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Results The frequencies reported in each of the categories ana- lyzed do not correspond to the total of studied Industry 4.0 cases.In this way, it is emphasized that the breadth of Industry 4.0 implementation in organizations goes beyond a specific application of a certain types of technology, extending to a holistic and integrated approach to technologies that meet all the needs of a digital production system.This result reinforces the breadth of the Industry 4.0 concept, which goes beyond the traditional areas of manufactur- ing and technology, confirming its broader concepts that refer to value added across the value chain [6].This characteristic is due to the fact that Industry 4.0 cases observed are always aimed at promoting the flexibility of manufacturing sys- tems (Flexible Manufacturing Systems).Contributions of Industry 4.0 to operations management The analysis of Industry 4.0 cases distribution in the areas of operations management indicates a greater cases con- centration in the technology management, followed by Just-in-Time manufacturing and supply chain manage- ment areas (Table 3).This is the case of the German crane company Wolffkran that has equipped its cranes with the industrial router that can be controlled remotely offering greater flexibility for the production.This is a consequence of the fact that many cases incorporate more than one area of operations man- agement and use several technologies simultaneously.This difference in the frequency distribution is confirmed by the Chi-square test, which indicates a presence of dependence between frequency of cases and OM areas (?2 = 38.36; 4; p-value < 0.01).Another case reported by ThyssenKrupp presented contributions in both areas, technology management and Just-in-Time manufacturing.In addition, the company incorporates the Just-in-Time manufacturing area through the implementation of predictive maintenance into the system.All the analyzed cases present application in the area of technology management.4.1.
Results
The frequencies reported in each of the categories ana- lyzed do not correspond to the total of studied Industry 4.0 cases. This is a consequence of the fact that many cases incorporate more than one area of operations man- agement and use several technologies simultaneously. In this way, it is emphasized that the breadth of Industry 4.0 implementation in organizations goes beyond a specific application of a certain types of technology, extending to a holistic and integrated approach to technologies that meet all the needs of a digital production system.
4.1. Contributions of Industry 4.0 to operations management
The analysis of Industry 4.0 cases distribution in the areas of operations management indicates a greater cases con- centration in the technology management, followed by Just-in-Time manufacturing and supply chain manage- ment areas (Table 3). This difference in the frequency
distribution is confirmed by the Chi-square test, which indicates a presence of dependence between frequency of cases and OM areas (χ2 = 38.36; 4; p-value < 0.01). This result reinforces the breadth of the Industry 4.0 concept, which goes beyond the traditional areas of manufactur- ing and technology, confirming its broader concepts that refer to value added across the value chain [6].
All the analyzed cases present application in the area of technology management. This characteristic is due to the fact that Industry 4.0 cases observed are always aimed at promoting the flexibility of manufacturing sys- tems (Flexible Manufacturing Systems). This is the case of the German crane company Wolffkran that has equipped its cranes with the industrial router that can be controlled remotely offering greater flexibility for the production. In addition, the company incorporates the Just-in-Time manufacturing area through the implementation of predictive maintenance into the system. Another case reported by ThyssenKrupp presented contributions in both areas, technology management and Just-in-Time manufacturing. In this case, a fusion between the phys- ical world and the data networks is identified, creating a “cybernetic system” during the production of elevator parts. With the use of this technology, the company reports sustainable gains in production management, maintenance, logistic processes, reduction of noncon- formities, and energy savings.
The few cases in the area of quality management, we mainly identify the use of intelligent sensors and technologies aimed at reducing errors in the assembly processes or product development. Among the cases investigated, we can mention Volkswagen, which uses an augmented reality (AR) technology by means of cam- era glasses integrated into the picking process, result- ing in reduced errors, improved ergonomics conditions, and increased productivity. Although few cases present applications directed to the area of quality management, the expectancy is that the applications in the other areas contribute indirectly to the quality of the products and services offered by the companies.
4.2. Industry 4.0 maturity level and its contribution to operations management
Among the cases, the results show the monitoring matu- rity level is predominant in the sample analyzed (Table 4). This conclusion is corroborated by the significant associ- ation between frequency of the cases and their maturity level (χ2 = 166.56; 3; p-value < 0.01). The concentration of cases at the monitoring level indicates that the applica- tions are addressed to monitor and report information from the environment in real time, which is an incipient state in relation to the implementation of Industry 4.0 [66]. Despite the importance attributed to Industry 4.0 to increase productivity in international surveys [3,39], this result reveals that the use of these technologies is still incipient in companies. When analyzing the association between OM areas and the maturity levels, no significant
Table 3. frequency of application of Industry 4.0 technologies in the evaluated cases.
organizations do not consider the fourth industry revolu- tion in their own culture in order to detect and visualize new opportunities of improvements [101], also justifying the low level of maturity of the cases analyzed. A case of the maturity level optimization refers to the company’s HBM. It provides a flexible and simplified solution that allows monitoring and control of the entire production processes, as well as performing algorithms and critical quality calculations that allow the worker to identify and correct problems during manufacturing processes. For the maturity level autonomy, only the case of the Stanley Black & Decker company was identified, whose application is associated to technology management and supply chain management areas. The company uses IoT technologies to keep inventory level of materi- als and components low, through detailed information and greater visibility of materials status and locations. In addition, the system allows customers to track the status of their orders and to schedule delivery.
4.3. Industry 4.0 technologies and its contributions to operations management
The results show a predominance of the use of IoT tech- nologies, followed by CPS and mobile devices (Table 5). This prevalent usage of one type of technology over another is confirmed by the Chi-square test (χ2 = 162.27; 6; p-value < 0.001). Although the term Industry 4.0 is often used to implement CPS [7,54,58], IoT technologies are more widely used in the sample of cases analyzed. This regular utilization of IoT can be explained by the fact that this type of technology contributes to communication among the systems, also aiding in the operation of CPS, as well as several other types of applications. Moreover, the use of sensors technology incorporated into the IoT category is one of the most mentioned in the literature as an integral component of Industry 4.0 [1,28,60], and it is still necessary for the operation of CPS [7].
Although the additive manufacturing technology is important for Industry 4.0 [28,49,59], among the cases investigated it was not possible to identify its use. This characteristic maybe explained by the fact that this kind of technology is presenting a parallel and independent path of development, and is even mentioned by some authors as a new and independent industrial revolution [102,103].
OM areas
technology management Just-in-time manufacturing supply chain management operations strategy Quality management
Frequency Percentage
37 42.05 25 28.41 10 11.36 9 10.23 7 7.95
association was found (χ2 = 7.52; 12; p-value = 0.821). This result is confirmed by the absence of adjusted residuals greater than |1.96| in any of the possible combinations. It indicates that a greater concentration of cases with a level of maturity in a specific OM area was not ver- ified in the analyzed sample. Although the unfolding of Industry 4.0 has been promoted with a focus on the OM areas of Just-in-Time manufacturing (for produc- tion management) and technology management (for the promotion of FMS and robotics), a greater number of the uses was not observed in the sample in these areas. The generation of real-time data enables control of the industrial systems, therefore the analysis of this data can be applied in a vast scope in a company [97]. In addition, the concept of Industry 4.0 envisions the creation of smart products through smart processes, with applications in several fields, like energy, logistics, sustainable mobility, etc. [98]. The diversity of Industry 4.0 applications in the OM areas confirms the breadth of the possibilities of Industry 4.0 adoption expressed in its concepts. Moreover, the effect of the Industry 4.0 can be more extensive, affecting beyond production areas [99] and increasing performance of the companies and welfare [100].
There was a low frequency of cases classified on control and optimization maturity levels, and these few occurrences are registered in technology management and Just-in-Time manufacturing areas. Regarding the level of adoption Industry 4.0 technologies, the compa- nies within aerospace industry are recognized as hav- ing the highest maturity level of Industry 4.0 [23]. This level of performance is explained by the experience with high embedded technology of aerospace components, which enables the utilization of Industry 4.0 technolo- gies in manufacturing processes. A different scenario was observed in the cases analyzed in this research, wherein few cases have a high level of maturity. Therefore, most
Table 4. chi-square test for the association between maturity level of cases and oM areas.
JOURNAL OF INDUSTRIAL AND PRODUCTION ENGINEERING 261
OM Operations strategy
Monitoring
control
optimization
autonomy
total 37 26 9 10 7 89
notes: frequency (adjusted residuals).
Maturity Level of Industry 4.0 appli- cations
Technology man- agement
Just-in-time manu- facturing
Supply chain man- agement
Quality manage- ment
Total
28 (0.5) 6 (−0.6) 2 (−0.1) 1 (0.2)
18 (−0.5) 6 (0.6) 2 (0.5) 0 (−0.9)
8 (1.1) 1 (−0.6) 0 (−0.8) 0 (−0.5)
7 (−0.2) 2 (0.1) 0 (−0.8) 1 (1.8)
4 (−1.0) 65 2 (0.7) 17 1 (1.0) 5
0 (−0.4) 2
262 D. C. FETTERMANN ET AL.
Table 5. chi-square test for the association between Industry 4.0 technologies and oM areas. OM
Technologies
Iot
cyber-physical systems Mobile devices
cloud computing
data analysis and
processing augmented reality additive manufac-
Technology management
30 (0.1) 10 (−0.4) 8 (−0.2) 7 (0.3) 4 (0.0)
3 (0.5) 0 (0.0)
Just-in-Time manufacturing
22 (0.4) 10 (1.0) 5 (−0.5) 4 (−0.4) 2 (−0.6)
1 (−0.7) 0 (0.0)
Operations strategy
8 (−0.3) 3 (−0.1) 4 (1.1) 2 (0.1) 1 (−0.2)
0 (−0.9) 0 (0.0)
Supply chain management
7 (−0.8) 2 (−0.8) 3 (0.4) 3 (0.9) 2 (0.8)
1 (0.4) 0 (0.0)
Quality management
Total
turing
total 62 44 18 18 11 153
6 (0.5) 73
2 (0.0) 27 1 (−0.5) 21 0 (−1.2) 16
1 (0.4) 10
1 (0.9) 6 0 (0.0) 0
notes: frequency (adjusted residuals).
The Chi-square test does not identify a presence of association between the use of the previously men- tioned technologies and OM areas in the sample ana- lyzed. This result indicates that none of the technologies present a frequency lower or higher than expected in any of the OM areas. A presence of significant associa- tion between the use of CPS technology and the Just-in- Time manufacturing area was expected, confirming the statements presented in the literature [7,54]. Sometimes, the literature mentions this kind of system analogous to Industry 4.0 [7,54], even so it does not present a sig- nificantly higher frequency in this OM area. The litera- ture also suggests that the use of cloud computing can improve the performance of supply chain management [104], however, the sample analyzed did not confirm this association. Only three cases of cloud computing utiliza- tion in the supply chain management were found. Again, this result reinforces the need to bring to light the wide- spread opportunities of application these technologies in the companies’ business [98].
Among the areas of OM, the quality management presented the low frequency of technologies use. Sometimes, this result can be explained by the lack of information about the case that harms its classification. The other technologies, as cloud computing, data pro- cessing and augmented reality, are distributed among OM areas proportionally, except additive manufacturing that was not verified in any of the cases analyzed.
German automobile company Audi is a case with the use of IoT technologies in the areas of technology management and quality management. In this case, the company uses intelligent sensors to monitor the preci- sion in the assembly processes. The device proposed fol- lows the assembly line stages and provides advices and feedback to employees. Another example is the Fujitsu IT Company, whose solution is oriented to Technology Management and Operations Strategy areas. In the case of Fujitsu, it could be observed that projects can be tested using IoT. Further, the company also utilizes other technologies such as cloud computing, cloud ser- vice and big data to evaluate and control the environ- mental impact of its projects.
The use of CPS are prevalent in the successful cases analyzed, especially when related to technology man- agement and Just-in-Time manufacturing areas. One example is the case of the chemical company CHT, which provides a human–machine network interface system to monitor in real time the production and to register all parameters of processes. The reduction of manufac- turing costs as well as increase safety of all processes realized in the facility are also important consequences.
The analysis of the cases shows a concentration of the use of technologies in the technology management and Just-in-Time manufacturing areas. The cases classi- fied in the quality management area presented low use of technologies taking into consideration the fact that sometimes the cases do not provide sufficient evidence to identify the technologies used. In spite of the low number of technologies observed in the cases classified in the quality management area, it is expected that the implementation of Industry 4.0 in automation of manu- facturing processes could increase the precision of the activities, resulting in general quality enhancemen
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