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

Authors: Lavanya Bhatia, Akhil Das

Abstract: In today’s competitive manufacturing landscape, achieving operational excellence requires a strategic fusion of traditional process optimization and emerging digital technologies. Lean manufacturing, with its focus on waste elimination and process efficiency, has been a cornerstone in operational management for decades. Industry 4.0, characterized by automation, connectivity, and real-time data analytics, introduces intelligent tools for transforming operations. This paper explores the integration of Lean principles with Industry 4.0 technologies—forming hybrid frameworks that offer synergistic benefits. The study analyzes how digital tools such as IoT, AI, and cyber-physical systems enhance Lean tools like Value Stream Mapping (VSM), 5S, and Kaizen. Real-world implementations, challenges in integration, and key enablers for success are also discussed. The paper concludes by proposing a structured hybrid framework to guide industries in achieving sustained operational excellence.

Authors: L. Radhakrishna, N. Gopikrishna

Abstract: Research is aimed at developing a mechanism using a gear train that can be used for lifting weights and loads. For the purpose of driving load we made necessary calculations for achieving end results. Paper reveals in designing relevant components for worthful works at higher expectations and estimations. A thought of that made us to prepare a prototype to lift required loads with lesser efforts. Paper sheaths Design calculations of various components stated and Manufacturing of those elements.

Authors: Ramkumar P, Muthuaravind P, Neethivendhan A, Dr. B.A. Saravanan

Abstract: Wire cut electric discharge machining process (WCEDM) is one of the rapidly growing non-contact machining process. This process is much more suitable technique for complex shapes that would otherwise be difficult to produce with conventional cutting tools and also very small work pieces, where conventional cutting tools may damage the part from excess cutting tool pressure. There is no contact between tool and work piece, thus separate sections and weak materials can machined without any difficulty. This paper discusses the literature review on wire cut EDM (WCEDM) process. It encompasses process parameters, tool material, and mode of dielectric medium used and also reviews about the data analysis technique used and finally explains the future trends of WCEDM in research.

Authors: Yogita Sharma, Mohpreet Singh

Abstract: Today the aim of the manufacturing companies is to reduce all types of wastes which are; man, money, material and mechanical their properties through the system simplification, organizational potential by using modern techniques. To remain the market leader many types of refinements are used to make the product cheaper and system efficient. Now day, various automotive and cycle industry starts to use the plastic components instead of different costly and heavy metals. So in the chaotic scenario the natural fiber composites are widely used for this addible purpose.

Author: Mr. Rajiv D. Meena

Abstract :Abstract Supervisory Control and Data Acquisition (SCADA) systems play a pivotal role in enabling real-time monitoring, control, and automation of industrial processes in modern manufacturing setups. With the ongoing transformation towards Industry 4.0, the integration of SCADA systems with cyber-physical systems, IoT devices, and cloud computing platforms has gained momentum, enhancing the intelligence and responsiveness of manufacturing systems. This paper explores the core architecture of SCADA systems, their integration into advanced manufacturing practices, associated benefits, challenges, and case-based applications. Emphasis is placed on the emerging trends of SCADA interoperability, cybersecurity, and remote monitoring capabilities that align with smart manufacturing goals.

Keywords: SCADA, Advanced Manufacturing, Industrial Automation, Real-time Monitoring, Industry 4.0, Cybersecurity, Remote Access, Data Acquisition

Author: Dr. Reema Patil

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

Author: Dr. Harsha Kumar M.

Abstract: Real time SLM monitoring usually relies on photodiodes or cameras, yet acoustic signals offer deeper penetration into the melt pool. We deploy piezoelectric arrays to capture ultrasonic bursts, feeding them to a convolutional neural network that predicts porosity with 91 % F1 score. Hardware does not intrude on the build chamber, eliminating optical path contamination issues.

Keywords: Selective laser melting; Acoustic emission; In process monitoring; Convolutional neural network; Porosity prediction

Authors: Anil Mulewa, Vijay Gehlot, M. L. Jain

Abstract: In this paper, the continuous development of an army helmet and modifications in its design adapted in last decay by various researchers were studied and trying to suggest the best material and the design for the army helmet. This study is basically a comparative review of different research works according to some parameters i.e. comfort, fitting, weight, maintainability, ballistic limit, material etc.

Authors: Swapnil Jagade, Pankaj Patole, Sumit Patil, Suraj Pawar, Shalaka kulkarni, Omkar Kulkarni

Abstract: The main purpose of today’s manufacturing industries is to produce low cost, high quality products in short time. They mainly focused on achieving high quality, in term of part accuracy, surface finish, high production rate etc. So, the selection of optimal cutting parameters is a very important issue for every machining process in order to reduce the machining costs and increase the quality of machining products. This paper shows the literature review of a detail study on process parameter optimization in turning process using CNC. This study will help in understanding how the input process parameters of CNC affect on the response variables. One of the technique widely used for optimization of machining parameters is Taguchi and ANOVA approach help to determine which parameters are most significant.

Authors: Anjali Verma, Rohit Keshari

Abstract: The evolution of Industry 4.0 has dramatically reshaped the modern manufacturing landscape, emphasizing the need for intelligent, distributed, and autonomous decision-making systems. Multi-Agent Systems (MAS) have emerged as a pivotal solution, enabling decentralized control and enhancing operational efficiency through real-time collaboration and negotiation among autonomous agents. This paper explores the architecture, functionality, and implementation of MAS in autonomous manufacturing environments. It delves into the roles of individual agents, coordination strategies, communication protocols, and decision-making capabilities. The paper also evaluates real world use cases where MAS have successfully improved flexibility, reduced downtime, and supported predictive maintenance in smart factories. Challenges such as system complexity, interoperability, and cybersecurity risks are addressed, along with recommendations for future research.

Keywords: Multi-Agent Systems, Autonomous Manufacturing, Smart Factory, Distributed Control, Industry 4.0

Authors: Ms. Ridhima R. Mehta, Mr. Arvind K. Chauhan

Abstract: In today’s volatile and highly competitive market, the ability to adapt quickly to changing customer demands is critical for manufacturing enterprises. Flexible Manufacturing Systems (FMS) are engineered to deliver that adaptability by integrating computer-controlled machines, automated material handling, and real-time data exchange. This paper explores how FMS enables rapid product changes, reducing lead times, increasing customization capabilities, and maintaining high productivity. The study also discusses FMS architecture, real-world applications, challenges in deployment, and integration with emerging technologies like IoT and AI for further enhancement. The paper highlights industry case studies and proposes strategic pathways for small and medium enterprises (SMEs) to adopt FMS for agile production.

Keywords: Flexible Manufacturing System (FMS), Rapid Product Change, Automation, Industry 4.0, Agile Manufacturing

Author: Mr. Praveen G.

Abstract: Cloud-Based Manufacturing Systems (CBMS) have emerged as a transformative approach to modern industrial operations, integrating cloud computing with manufacturing resources and services. These systems enable flexible, scalable, and efficient production environments by virtualizing physical manufacturing assets and deploying them on demand through the internet. CBMS leverages technologies such as Industrial Internet of Things (IIoT), cyber-physical systems (CPS), and artificial intelligence (AI) to achieve a highly collaborative and intelligent production ecosystem. This paper explores the architecture, benefits, challenges, and future directions of cloud based manufacturing systems, highlighting their role in achieving smart, sustainable, and globally connected manufacturing operations.

Keywords: Cloud Manufacturing, Cyber-Physical Systems, IIoT, Smart Factory, Virtualization, On-Demand Production

Authors: Dr. A. Meenalatha, Mr. YashwantJadhav, Ms. Kavitha Elango

Abstract: The digital thread is rapidly emerging as a transformative enabler in modern manufacturing and engineering, especially within the framework of Product Lifecycle Management (PLM). By establishing a seamless, traceable, and interconnected flow of data across a product's lifecycle—from concept to retirement—the digital thread supports real-time decision-making, enhances product quality, reduces time-to-market, and fosters innovation. This paper explores the conceptual foundations of the digital thread, its integration with PLM systems, enabling technologies such as IoT, digital twin, and cloud computing, and its impact on design, manufacturing, and service stages. It also discusses implementation challenges, data interoperability issues, and security concerns, concluding with future research directions and recommendations for industry adoption.

Keywords: Digital Thread, Product Lifecycle Management (PLM), Digital Twin, Smart Manufacturing, Data Interoperability, Industry 4.0

Authors: Mr. Aravind M, Sneha R. Patil

Abstract : Zero-defect manufacturing (ZDM) represents a transformative approach aimed at eliminating defects during the production process rather than correcting them post-production. This paper explores the integration of digital feedback loops—a continuous data-driven mechanism that captures real-time performance, quality deviations, and equipment behavior to proactively correct anomalies before defects occur. By leveraging industrial Internet of Things (IIoT), artificial intelligence (AI), and advanced process analytics, manufacturers can close the loop between production data and corrective action. The study outlines the architecture of digital feedback systems, their deployment in different industrial sectors, and the benefits in quality assurance, cost reduction, and predictive control. Through a critical analysis of case studies and recent technological advancements, the paper provides a comprehensive roadmap for adopting ZDM in smart manufacturing environments.

Keywords: Zero-defect manufacturing, digital feedback loops, quality assurance, Industry 4.0, predictive analytics, smart manufacturing, IIoT, real time monitoring.

Author: Dr. Sruthi Nair

Abstract: Cyber-Physical Systems (CPS) represent the backbone of Industry 4.0, enabling seamless integration between the physical world of manufacturing and its digital twin. These systems combine embedded sensors, intelligent control units, and networked communication to form a unified framework capable of self-monitoring, autonomous decision-making, and real-time adaptation. This critical review paper investigates the role of CPS in transforming conventional manufacturing into smart, connected, and context-aware environments. It outlines core technologies, explores use cases across key sectors, and analyzes systemic challenges and strategic opportunities. The study also critiques existing CPS architectures and highlights how integration with AI, IoT, and cloud computing strengthens operational agility. Concluding with a vision for Industry 5.0, this review offers insights into how CPS is reshaping the industrial future by blurring boundaries between the physical and digital domains.

Keywords: Cyber-Physical Systems, Industry 4.0, Digital Twin, Smart Manufacturing, Real-Time Control

Author: Dr. K. Haripriya

Abstract: The integration of sustainable manufacturing systems with green technology has become a crucial priority in the era of Industry 4.0. With increasing global concerns about climate change, environmental degradation, and resource depletion, industries are undergoing a transformative shift towards more sustainable and efficient practices. This paper examines the strategic role of sustainable manufacturing systems in facilitating environmentally responsible production, highlighting how green technology, smart automation, and digital tools are enabling this shift. The study reviews key literature on the subject, identifies current challenges, explores the vast scope of applications, and outlines the essential components and future directions for sustainable industrial practices. It proposes a framework where innovation, digitization, and sustainability converge, thereby redefining the manufacturing paradigm for long-term ecological balance and economic growth.

Keywords: Sustainable Manufacturing, Industry 4.0, Green Technology, Smart Factories, Environmental Efficiency

Authors: Dr. Tanmay R. Kulshreshtha

Abstract: The Industrial Internet of Things (IIoT) has emerged as a transformative enabler for advanced manufacturing systems. IIoT involves a network of interconnected devices and machinery embedded with sensors that collect, share, and analyze data across the production value chain. This paper presents the architecture of IIoT-enabled factories, focusing on how real-time data collection and edge computing enhance efficiency, reduce waste, and improve quality control. It highlights the integration of IIoT with cloud platforms and artificial intelligence for predictive analytics, autonomous control, and asset tracking. Case studies from manufacturing sectors demonstrate how IIoT leads to smarter maintenance practices, energy optimization, and reduced downtime. Regulatory and cybersecurity concerns are also analyzed to identify barriers and propose mitigation strategies.

Keywords: Industrial IoT, Sensor Networks Edge Computing, Smart Maintenance, Real-Time Analytics

Authors: Prof. N.D. Patil, Prof. N.V. Hargude, Prof. A.M. Patil

Abstract:In the automobile sector, the weight of vehicles is increasing due to large-scale use of steel & iron. Due to competition in vehicle manufacturing, all manufacturers try to reduce the weight of automobile components. They search for new materials that can be used for reducing weight. These include fibers, plastics, composite materials etc. In this research paper, we focus on one of these materials, the leaf spring. Generally, leaf spring is manufactured by using MS material with a number of leafs, but we require only one leaf in composite materials as that is sufficient to sustain the entire vehicle’s weight. In this research paper, a study of load deflection on single epoxy carbon glass fiber composite material is presented. The objective of this research paper is to compare load carrying capacity and stiffness to weight ratio.

Authors: Jaydeepsinh J Vaghela, Yuvrajsinh L Raol

Abstract :To save energy and to protect the global environment, fuel consumption reduction is a primary concern of the modern truck manufacturers. Drag reduction is essential for reducing fuel consumption. Designing a vehicle with a minimized drag resistance leads to advantages of fuel economy and performance improvement. The shape is an important factor for drag reduction. To design a shape for an efficient truck that gives low resistance when moving forward, the most important functional requirement to consider is low fuel consumption. The resistance, termed as the drag force (or the drag coefficient in non dimensional terms), is a strong function of the shape of the truck. The main purpose of the project on which this paper is presented, was to reduce the drag co-efficient (CD) and drag force (FD) of a truck’s body by improving the aerodynamic shape using CFD software (Autodesk Flow Design). The difference of FD as well as CD before and after the change in aerodynamic shape of truck is carried out at different speeds. We got the desirable results for the reduction of drag force - about 12 to 15%.

Keywords: Optimization, Autodesk Flow Design, Drag Force, Drag Co-Efficient, Fuel Consumption, Non Dimensional, Drag Reduction ,Aerodynamics