Journal of Advance Manufacturing System and Technology ISSN: 3107-8133 (Online)

Authors : Dr. ReemaPatil , Mr. Ashwin Menon ,

              Ms. Shruti Kulkarni

Abstract : The integration of Human-Robot Collaboration (HRC) in Flexible Manufacturing Systems (FMS) is rapidly reshaping the industrial landscape under the umbrella of Industry 4.0. This paper investigates how humans and robots are working together to create responsive, efficient, and intelligent manufacturing environments. Traditional manufacturing relied on rigid automation, but modern FMS demands adaptable solutions where human flexibility and robotic precision coexist. The paper explores various collaborative models, key enabling technologies, benefits, and safety frameworks. It also highlights current challenges like ethical concerns, skill gaps, and integration complexities while proposing pathways for future research and implementation. By bridging the strengths of human cognition and robotic efficiency, HRC in FMS is not only improving productivity but also transforming shop-floor dynamics to foster a more resilient manufacturing ecosystem.

Keywords:    Human-Robot Collaboration, Flexible Manufacturing Systems, Industry 4.0, Collaborative Robots, Smart Manufacturing, Safety Protocols, Industrial Automationn

Authors : Mr. R. Sanket Kumar , Dr. Priya Shekhar,                                Ms. Neelam Joshi

Abstract : Waste minimization is a critical objective in modern industrial practices as industries face increasing pressure to improve resource efficiency, reduce environmental impact, and enhance economic performance. This paper investigates the integration of Lean and Green manufacturing principles as a comprehensive approach for achieving waste minimization in manufacturing systems. Lean focuses on reducing non-value-added activities, while Green emphasizes minimizing environmental impacts. Together, they offer a powerful synergy to eliminate different forms of waste—ranging from material and energy to emissions and time. The study explores key Lean and Green tools, their overlapping concepts, and real-world industrial implementations. Case studies from different sectors, including automotive, electronics, and process industries, are reviewed to highlight the effectiveness of this integrated approach. The paper concludes with a roadmap for industries aiming to adopt Lean-Green integration and highlights the challenges and benefits in the path to sustainable manufacturing.

Keywords:    Lean manufacturing, Green manufacturing, waste minimization, sustainable production, value stream mapping, eco-efficiency.

Author : Ms. Praveena T.

 Abstract : Digital simulation has emerged as a transformative tool in the quest for industrial excellence, enabling real-time visualization, analysis, and enhancement of complex processes. By replicating real-world operations in virtual environments, industries can test variables, optimize resource allocation, and minimize waste without physical disruptions. This paper explores the theoretical underpinnings of digital simulation, tools commonly employed, and case studies that demonstrate its efficacy in diverse sectors like manufacturing, healthcare, logistics, and construction. A particular emphasis is placed on discrete event simulation, agent-based modeling, and system dynamics as leading techniques. The paper further analyzes how simulation integrates with modern technologies like IoT, AI, and digital twins to foster adaptive, lean, and efficient systems. It concludes with discussions on limitations, future scope, and ethical considerations, asserting digital simulation as a cornerstone of modern process optimization strategies.

Keywords:    Digital Simulation, Process Optimization, Digital Twin, Discrete Event Simulation, Industry 4.0, System Modeling, Predictive Analytics, Lean Manufacturing

Author : Dr. Kavita Menaria

Abstract : Manual lay up of carbon fibre plies remains labour intensive and error prone. We overlay high contrast seam lines and overlap cues onto smart glasses, driven by depth sensor alignment. In trials, novice operators achieved 4.8 mm mean positional error—comparable to experts—and cut rework hours by 40 %. Subjective workload scores also declined.

Keywords:    Augmented reality; Composite lay up; Human factors; Depth sensing; Mixed reality

Author: Saloni Saini

Abstract: The fourth industrial revolution, commonly referred to as Industry 4.0, is transforming manufacturing systems into interconnected, data-driven, and intelligent environments known as Cyber-Physical Systems (CPS). These systems blend physical processes with digital computation and communication networks, allowing real-time monitoring, decision-making, and adaptive control. CPS in manufacturing creates a smart factory ecosystem where sensors, actuators, embedded software, and cloud services work in harmony. This paper presents a comprehensive analysis of how CPS enables features like digital twins, real-time analytics, remote diagnostics, and intelligent logistics. The study highlights the significance of system interoperability, secure communication protocols, and edge computing in ensuring seamless integration. Case studies from sectors such as pharmaceuticals, electronics, and heavy machinery demonstrate the impact of CPS on operational agility and product customization. Furthermore, the paper addresses the challenges of data standardization, system scalability, and workforce training, while suggesting policy recommendations and technology roadmaps for accelerating CPS adoption across manufacturing domains.

Author: Raghavendra M. Naik

Abstract: The evolution of advanced manufacturing systems has been significantly accelerated through the integration of Artificial Intelligence (AI) technologies such as machine learning, deep learning, neural networks, and intelligent robotics. These tools have revolutionized the way industries design, produce, monitor, and optimize production processes. Unlike traditional automation, AI enables machines to adapt, learn, and make decisions based on data-driven insights, leading to smarter manufacturing floors with predictive maintenance, real-time quality assurance, and autonomous decision-making. The deployment of AI in manufacturing not only minimizes human error and downtime but also enhances flexibility and scalability. This paper delves deep into the synergistic relationship between AI algorithms and manufacturing systems, highlighting successful industrial case studies across automotive, aerospace, and precision tools sectors. Furthermore, it explores the key challenges industries face during AI adoption, such as data availability, system interoperability, cybersecurity threats, and the skill gap in workforce. Emphasis is placed on the transition from reactive to predictive manufacturing, setting the stage for self-optimizing factories of the future.

Keywords: Artificial Intelligence, Smart Manufacturing, Process Optimization, Predictive Maintenance, Industry 4.0

Authors:-Prof. Dr. Nemailal Tarafder

Abstract:-Material handling equipment (MHE) is mechanical equipment used for movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. Material handling equipment are divided into four major groups, such as transport equipment, positioning equipment, unit load formation equipment and storage equipment. Engineered system cover a variety of units that work cohesively to enable storage and transportation. They are often automated. A company’s material handling system and processes are put in place to improve customer service, reduce inventory, shorter delivery time and lower overall handling costs in manufacturing, distribution and transportation. Toyota Industries meets diverse customers’ needs in logistic by providing a diverse range of material handling equipment. Laxmi Steel offers a complete choice of products which includes material handling system, drum handling system and textile material handling equipment. A. T. E’s products offered include platform trucks, hand pallet trucks, manual and electrical stackers, hand pallets, dock levelers, reach trucks, electric forklifts, scissor lifts, custom built trucks and racking systems. The material handling equipment followed by the spinning mills differ widely. Modern mills have been using appropriate material handling equipment. A right material handling system across the factory departments reduces material transportation time, waiting time at work and delays.

Authors: Ch. Ranga Rao, B Srinivasulu

Abstract: Development of light materials is challenging. Numerous applications has been developed for creating light weight materials which can be used in Aircraft industry, automobile industry, satellite launching, mobile assembly applications. This can be achieved by Friction Stir Welding is a solid state joining process. In this process a rotating tool is plunged in to the work piece, because of the friction between tool and work piece a considerable heat is developed which is sufficient to melt the metal and join which is free from fumes, gases or oxides. An experiment has been conducted on a conventional milling machine for joining of Aluminum(6061-T6) with Brass and welded samples are tested found that Square profile has given better Tensile Strength and  Yield Strength but Diamond profile has given better Hardness.

Keywords: Friction stir welding (FSW),EN 19 Tool, Diamond and Square profile.

Authors:-Arun Kumar Singh, Rajesh Kumar

Abstract:-Various welding process are present, among the various welding process, Tungsten inert gas (TIG) welding plays a major role in the welding of mild steel or thin sections of non-ferrous metals such as copper alloys, aluminium alloys, magnesium and stainless steel. MIG input welding parameters are the most important factors affecting the quality of the welding and weld quality is strongly characterized by weld bead geometry. The choice of the welding depends on several factors; primarily among them are the compositional range of the material to be welded, the thickness of the base materials and type of current. TIG welding has several advantage like joining of dissimilar metals, the absence of slag, low heat affected zone and etc. Since input parameters play a major role in determining the quality of a welded sample. A plan of experiments based on Taguchi technique has been used to design of experiment, acquire the data and to optimize the welding parameters as well as the process. An Orthogonal array and analysis of variance (ANOVA) are employed to investigate the welding characteristics of alloy Steel material and predict the welding parameters. Properties are Hardness, Tensile strength etc. are taken as responses of input parameter. Finally the comparison tests have been carried out to compare for given alloy steel with the ANOVA values for prediction of parameter its effectiveness in the analysis of penetration.

Author: Dr. Kartik R. Vaidya

Abstract: Multi-axis machining is a transformative technology in precision manufacturing, allowing complex geometries and high surface quality. However, its success depends on stringent control of multiple variables. Adaptive Process Control (APC) has emerged as a powerful solution to manage dynamic variations in tool wear, cutting forces, and thermal effects during machining. This paper explores the integration of APC systems in multi-axis machining environments, highlighting their ability to modify cutting parameters in real-time based on sensor feedback. Techniques like model-based control, AI-driven optimization, and real-time monitoring are discussed in detail. The implementation of APC not only improves surface finish and dimensional accuracy but also reduces downtime and enhances tool life. The study concludes by presenting current industrial trends and future directions in adaptive machining systems.

Keywords: Adaptive Process Control, Multi-Axis Machining, Real-Time Monitoring, Tool Wear Compensation, Intelligent Manufacturing

Authors: Edwin Raja Dhas, J., Pradeep, P.

Abstract: Advanced fibrous polymeric composites are one of the most successful composite material systems due to its wide range of advantages such as high specific strength and stiffness, fatigue properties and corrosion resistance. The polymer matrix is more susceptible to these changes than the fiber and thus dominates the mechanical behavior of FRP composites. Polymers are characterized as visco-elastic materials that their mechanical properties are strain rate dependent. The present experimental study aims at learning the mechanical behaviour of alkali treated chopped palm leaf stalk natural fiber polymer composites. Samples of are manufactured using hand layup method and the weight fraction of matrix and fiber is kept at 30% to 70%.Specimens are cut from the fabricated laminate according to the ASTM standards for different experiments like tensile test, flexural test, impact test and hardness test. Experiments are performed in a computerized Universal testing machine, Charpy Impact tester and Hardness tester. Result shows that, the trend in all the properties increased for alkali treated chopped fibers except for hardness value.

Keywords: Composites, Palmyra, Alkali, Mechanical Properties, Visco-elastic materials

Authors: Shalini Verma, Satish Kumar

Abstract: The global increasing demand for refrigeration in field of refrigeration air-conditioning, food preservation, vaccine storages, medical services, and cooling of electronic devices, led to production of more electricity and consequently more release of CO2 all over the world which it is contributing factor of global warming on climate change. The prices of energy have been increasing exponentially worldwide. Industrial Refrigeration is one of the most energy consuming sector. What if a refrigeration system is designed which uses no energy or minimal amount of energy? The solution lies in absorption refrigeration system. By producing an absorption refrigeration system we are not only cutting down the energy costs but also preserving our environment. This refrigeration system doesn’t use any of the CFCs so our ozone layer is safe. This paper studies about LiBr/water based absorption refrigerator designed for rural application and applies solar rays based on reverse seebak effect.

Keywords: Advanced Refrigerator, LiBR/water, Seebak Effect

Authors: Vasudha Singh, Kavita Shrivastav, Priti Singh

Abstract: Laser machining is key in today's propelled producing, and made the requirement for littler openings, littler lands, smaller lines and spaces, littler and more controllable spot than any other time in recent memory. Investigation of laser pillar association with materials empowers us to investigate the physical procedures included, better comprehends the laser machining process, and might be dispense with some undesirable reactions and increment proficiency of the machining process. This examination endeavors to lessen the exploratory time and cost connected with setting up process parameters for appointing the central spot and shaft measurement. The examination performed in this work taking into account the explanatory and also trial arrangements system. From the readings got from arrangement of tests with 1% force ought to be alluded for the count.

Keywords: Fiber Laser, Focal Position, Cutting Process

Authors: Amol Suresh Nankar, D. A. Deshmukh

Abstract: Cutting operation is very essential aspect in manufacturing scenario. Application of coating on tool surface helps to improve tribological properties of surface such as wear and coefficient of friction of the surface. Cutting life time of a tool material is significantly affected by wear. The performance of various coatings on tool material is inspected by studying the variation of its two properties viz. wear & coefficient of friction. These essential tribological properties have been evaluated by using pin on disc test. This paper is focused on various low friction coatings such as TiN, CrN and DLC coating on High speed steel T-42 pin as a base material. This paper deals with the study of performance parameters like speed, sliding distance and load compared between different coated HSS-T42 pin base materials. Taguchi method is used under the performance parameter & L9 orthogonal array is selected to perform experiment on pin on disc of the specimen. The EN31 steel material is selected as work piece material. The response value found out by using coefficient of friction which was obtained from pin on disc test. Scanning Electron Microscopy (SEM) analysis for compared different coated pin for micro structural test.

Keywords: HSS T-42 pin, Wear, Coefficient of Friction, TiN, CrN, DLC.

Author: Dr. Raghav Meena

Abstract: Micro and nano-manufacturing have emerged as revolutionary fields transforming industries like electronics, biomedicine, automotive, aerospace, and precision engineering. These advanced techniques allow the fabrication of components and structures at the micro and nanometer scale with high accuracy, precision, and material efficiency. This paper provides a comprehensive review of major micro and nano-manufacturing techniques, including photolithography, nanoimprint lithography, focused ion beam machining, and laser-assisted processes. Key challenges such as scalability, cost-effectiveness, and material limitations are addressed. The paper also highlights the applications and future scope of these technologies in critical sectors like healthcare and semiconductors.

Keywords: Micro-manufacturing, Nano-manufacturing, Lithography, MEMS, Precision Engineering, Nanotechnology

Author: Ms. Kalyani Sharma

Abstract: Quantum-inspired optimisation (QIO) offers a novel approach to enhance the efficiency of tool path planning in modern CNC machining. Specifically, in 5-axis milling, where simultaneous movement along multiple axes enables complex surface machining, path redundancy and time-consuming operations remain significant bottlenecks. This paper explores the application of quantum-inspired algorithms, particularly leveraging superposition and probabilistic search strategies, to optimise and compress tool paths without compromising surface quality. Through the fusion of classical heuristics and quantum-inspired computational models, this study demonstrates enhanced precision, reduced tool wear, and minimized machining time. The investigation includes a comparative study with conventional methods and outlines the potential of QIO in intelligent manufacturing ecosystems

Keywords: Quantum-Inspired Optimisation, 5-Axis Milling, Tool Path Compression, Complex Surface Machining, CNC Toolpath Efficiency

Authors:-S. Anivel, Dr. K. Manivannan

Abstract:-In this work a general idea about decision making models and Analytical Network Process (ANP) are introduced. The Analytic Network Process (ANP) is a general theory of relative measurement used to derive priority ratio scales. Through its super matrix whose elements are themselves matrices of column priorities, the ANP captures the outcome of dependence within clusters of elements. The ANP is a new phase in decision making, neglected so far because of the linear structures used in traditional approaches and their inability to deal with feedback in order to choose alternatives. In this paper we will be using ANP to measure performance of cement production industry.

Author: Shahaji Bhosale

Abstract: This paper presents the literature review of hydrodynamic journal bearing. Hydrodynamic Journal bearing is a power transmission component that carries high load in different machineries. It is essential to study the performance characteristics under different loading and operating conditions. The behavior of Hydrodynamic Journal Bearing is also dependent on lubricant used. Lubricant additives play a major role in improving the tribological properties of modern day lubricants. Considering present day energy scenario and the ever increasing severity in operating conditions of machineries, it is imperative that we develop better tribological practices leading to reduced losses due to friction and wear. Journal bearings, being the more popular support mechanism in high speed applications, have been the focus of research of many tribologists

Keywords: Nanoparticles, Tribological Properties, Engine Oil, Friction Coefficient

Authors: Nitesh M. Kathar, Avinash U. Karadkhele

Abstract: The Electrical Discharge Machining process is employed widely for making tools, dies and other precision parts. EDM has been replacing drilling, milling, grinding and other traditional machining operations and is now a well established machining option in many manufacturing industries throughout the world. And is capable of machining geometrically complex or hard material components, that are precise and difficult-tomachine such as heat treated tool steels, composites, super alloys, ceramics, carbides, heat resistant steels etc. being widely used in die and mould making industries, aerospace, aeronautics and nuclear industries. Electric Discharge Machining has also made its presence felt in the new fields such as sports, medical and surgical, instruments, optical, including automotive R&D areas. The following study was carried out to review the work of various researchers performed on EDM.

Author :Dr. Kruthika Rajan

Abstract :Hybrid manufacturing lines—particularly those integrating laser cladding, precision milling, and automated inspection—present complex and interdependent flows of energy, materials, and emissions. These flows are typically non-linear and vary widely with process parameters such as re-clad depth, machine state transitions, and energy source fluctuations. To quantify and analyze these real-time variabilities, we present a novel integration of line-side programmable logic controller (PLC) data with internationally recognized emission benchmarks, specifically ISO 14067 standards for product carbon footprinting. Our approach enables high-resolution, second-level carbon footprint dashboards that reflect the instantaneous environmental impact of each machining operation. These dashboards fuse process-specific energy metrics (e.g., spindle power, gas flow, thermal cycles) with dynamic emission factors, allowing for transparent and time-synchronized carbon tracking throughout the production lifecycle.
A pilot deployment on a turbine blade remanufacturing cell revealed significant insights: the carbon footprint per part exhibited a variance of ±12%, primarily driven by differences in re-cladding volume and energy consumed during post-processing. Such fine-grained carbon accounting not only enhances environmental transparency but also enables data-driven decisions in procurement and supplier evaluation. Specifically, the variability captured in per-part emissions provides a robust foundation for implementing dynamic eco-supplier rating systems, where vendors can be ranked and rewarded based on verified real-time sustainability performance. This framework demonstrates how hybrid manufacturing environments can transition from static environmental reporting to live, actionable insights that drive greener and more accountable production strategies

Keywords: Carbon footprint; Hybrid machining; PLC integration; Sustainability dashboard; Turbine repair

Author: A. Sreenivasa Rao

Abstract :This paper shows the influence of the elastic spring back on, displacement, tool wear and surface roughness of titanium alloy with high cutting speeds in CNC milling operation. At these high cutting speeds, the chemical and mechanical properties of Ti6Al4V cause complex wear mechanisms. In this work, a carbide two flute end mill tool is tested, and its wear behavior is studied. The performance of the carbide tool has been investigated in terms of tool life, displacements, spring back and surface roughness. A slower wear progression was found with an increase in cutting speeds, whereas the norm is an exponential increase in tool wear at elevated speeds. Observations based on scanning electron microscope (SEM) analysis shows that the spring back effect plays a major role in vibrations, surface roughness and tool wear.

Keywords: CNC end Milling, tool wear, high speed, carbide tool, spring back effect, Vibration displacement and tool wear

Authors: N. Janardhan

Abstract: To evaluate the performance of diesel engine with high grade low heat rejection combustion chamber which consisting of air gap insulated piston with 3 mm air gap, with superni (an alloy of nickel) crown, air gap insulated liner with superni insert and ceramic coated cylinder head with neat diesel with varied injection pressure experiments were carried out. Performance parameters brake thermal efficiency, exhaust gas temperature, coolant load, volumetric efficiency and sound levels were determined at different values of brake mean effective pressure (BMEP) of the LHR–3 combustion chamber and compared with neat diesel operation on conventional engine (CE) at similar operating conditions. It is also found that Engine with LHR–3 combustion chamber with neat diesel operation showed deteriorated performance at manufacturer’s recommended injection timing of 27o bTDC.The Injection pressure changed from 190bar to 270bar with an increment of 40bar.

Author:Priyanka P. Gangurde

Abstract: Statistical process control (SPC) techniques are employed to monitor production process over time to detect changes in process performance. SPC helps ensure the process operates efficiently, producing more specification conforming products with less waste. SPC applied to any process where the ‘conforming products’ output can be measured. Key tools used in SPC includes run chart, control chart, a focus on continuous improvement. In industry, during machining of the component some defects are occurs due to blunt tool, so there is rejection of that component , hence to overcome this problem there is need to implement the SPC with its technique of control chart such as XÌ…and R chart . The sharda motors is the industry in which the parts of automobile suspension system are manufactured. In this industry, during boring operation of suspension system (upper control arm 105), some variations are occurred in the dimensions of components. Due to this there is rejection of that component. Hence there is need to implement such a quality method which gives early detection and prevention of problems rather than the correction of problem after they have occurred.

Authors: P. A. Jaiswal, Dr. T. R. Deshmukh

Abstract:The increasing trends and demands in the automotive world, there is always tug and tie between the designer and customer. To cope with the existing competition in the modern times there is always need for great improvement in compatibility of the engine models. The efficiency of IC Engine is reduced and fuel consumption is increased. The Lots of research works are carried out to increase the efficiency of IC Engine and reduce fuel consumption by using method such as Laser Surface Textured (LST) method, Thermal Barrier Coating (TBC) method. Piston is the one of the main part of IC engine. The function of piston is transfer the pressure to the crank through the connecting rod. Generally piston is made by cast iron and aluminum alloy. As we know that by using of ceramic material coating on piston, the performance of IC Engine can be increased. The study is a comparative evaluation was made between the temperature distributions of the uncoated aluminum silica alloy piston and the ceramic coated piston. The Ansys is done by using Ansys 16.0 software.

Author: Kunal A. Patange

Abstract: Additive Manufacturing (AM), commonly known as 3D printing, represents a revolutionary shift in how components are designed, prototyped, and produced. Unlike subtractive methods, AM constructs parts layer-by-layer, offering design freedom, minimal material waste, and rapid customization. This paper explores the various additive technologies—fused deposition modeling, selective laser sintering, and stereolithography—highlighting their suitability across industries such as aerospace, healthcare, and automotive. Emphasis is placed on the growing trend of integrating AM into existing manufacturing ecosystems to support low-volume, high-complexity part production. Moreover, the paper investigates current limitations, including material constraints, surface finish quality, and scalability challenges. Finally, it discusses ongoing research aimed at overcoming these barriers and enhancing AM's industrial applicability.