Additive manufacturing (AM), an enabler of Industry 4.0, recently opened limitless possibilities in various sectors covering personal, industrial, medical, aviation and even extra-terrestrial applications. Although significant research thrust is prevalent on this topic, a detailed review covering the impact, status, and prospects of artificial intelligence (AI) in the manufacturing sector has been ignored in the literature. Therefore, this review provides comprehensive information on smart mechanisms and systems emphasizing additive, subtractive and/or hybrid manufacturing processes in a collaborative, predictive, decisive, and intelligent environment. Relevant electronic databases were searched, and 248 articles were selected for qualitative synthesis. Our review suggests that significant improvements are required in connectivity, data sensing, and collection to enhance both subtractive and additive technologies, though the pervasive use of AI by machines and software helps to automate processes. An intelligent system is highly recommended in both conventional and non-conventional subtractive manufacturing (SM) methods to monitor and inspect the workpiece conditions for defect detection and to control the machining strategies in response to instantaneous output. Similarly, AM product quality can be improved through the online monitoring of melt pool and defect formation using suitable sensing devices followed by process control using machine learning (ML) algorithms. Challenges in implementing intelligent additive and subtractive manufacturing systems are also discussed in the article. The challenges comprise difficulty in self-optimizing CNC systems considering real-time material property and tool condition, defect detections by in-situ AM process monitoring, issues of overfitting and underfitting data in ML models and expensive and complicated set-ups in hybrid manufacturing processes.

Background: Additive manufacturing (AM) applications in producing spare parts are increasing day by day. AM is bridging the digital and physical world as a 3D computer-aided manufacturing (CAM) method. The usage of AM has made the supply chain of the aviation spare parts industry simpler, more effective, and efficient. Methods: This paper demonstrates the impacts of AM on the supply chain of the aircraft spare parts industry following a systematic literature review. Hence, centralized and decentralized structures of AM supply chains have been evaluated. Additionally, the attention has been oriented towards the supply chain with AM technologies and industry 4.0, which can support maintenance tasks and the production of spare parts in the aerospace industry. Results: This review article summarizes the interconnection of the industry findings on spare parts. It evaluates the potentiality and capability of AM in conceptualizing the overall supply chain. Moreover, MROs can adopt the proposed framework technologies to assist decision-makers in deciding whether the logistics hub with AM facilities is centralized or decentralized. Conclusions: Finally, this review provides an overall view to make critical decisions on the supply chain design of spare parts driven by new and disruptive technologies of industry 4.0. The next-generation supply chain may replace the logistics barriers by reducing waste and improving capability and sustainability by implementing AM technologies.

The emerging technologies of Industry 4.0 (I4.0) are crucial to incorporating agility, sustainability, smartness, and competitiveness in the business model, enabling long-term sustainability practices in the pharmaceutical supply chain (PSC). By leveraging the latest technologies of I4.0, pharmaceutical companies can gain real-time visibility into their supply chain (SC) operations, allowing them to make data-driven decisions that improve SC performance, efficiency, resilience, and sustainability. However, to date, no research has examined the critical success factors (CSFs) that enable the pharmaceutical industry to adopt I4.0 successfully to enhance overall SC sustainability. This study, therefore, analyzed the potential CSFs for adopting I4.0 to increase all facets of sustainability in the PSC, especially from the perspective of an emerging economy like Bangladesh. Initially, sixteen CSFs were identified through a comprehensive literature review and expert validation. Later, the finalized CSFs were clustered into three relevant groups and analyzed using a Bayesian best-worst method (BWM)-based multi-criteria decision-making (MCDM) framework. The study findings revealed that "sufficient investment for technological advancement", "digitalized product monitoring and traceability", and "dedicated and robust research and development (R&D) team" are the top three CSFs to adopt I4.0 in the PSC. The study’s findings can aid industrial practitioners, managers, and policymakers in creating effective action plans for efficiently adopting I4.0 in PSC to avail of its competitive benefits and ensure a sustainable future for the pharmaceutical industry.

Background: Fast-moving consumer goods (FMCG) supply chains are experiencing various challenges due to the interactions between consumers and decision-makers during physical distribution, manufacturing, wholesale and retail. One possible strategy to address these challenges for smoothing the supply chain (SC) and logistics operations is to adopt Industry 4.0 (I4.0) based technologies in the FMCG business processes. In this regard, digitalization and automation of the FMCG supply chain can be strengthened by the alluring properties of I4.0 technologies. Methods: This study identified nine significant challenges through a literature review and expert validation. Later, the challenges were evaluated using a novel multicriteria decision-making (MCDM) framework, the Bayesian best worst method (BWM). Results: The findings indicated that “requirement for substantial investment and resources”, “incompatible technological infrastructure” and “poorly structured value chain” are the most significant challenges to implementing I4.0 in the FMCG industry. Conclusions: The study is expected to significantly contribute to improving the FMCG supply chain’s resilience, sustainability, visibility, traceability and responsiveness. Additionally, the research can provide industrial practitioners valuable insights into implementing I4.0 in FMCG and similar sectors and thus promote SC sustainability and resilience in those industries.

With the advancement of additive manufacturing (AM), or 3D printing technology, manufacturing industries are driving towards Industry 4.0 for dynamic changed in customer experience, data-driven smart systems, and optimized production processes. This has pushed substantial innovation in cyber-physical systems (CPS) through the integration of sensors, Internet-of-things (IoT), cloud computing, and data analytics leading to the process of digitization. However, computer-aided design (CAD) is used to generate G codes for different process parameters to input to the 3D printer. To automate the whole process, in this study, a customer-driven CPS framework is developed to utilize customer requirement data directly from the website. A cloud platform, Microsoft Azure, is used to send that data to the fused diffusion modelling (FDM)-based 3D printer for the automatic printing process. A machine learning algorithm, the multi-layer perceptron (MLP) neural network model, has been utilized for optimizing the process parameters in the cloud. For cloud-to-machine interaction, a Raspberry Pi is used to get access from the Azure IoT hub and machine learning studio, where the generated algorithm is automatically evaluated and determines the most suitable value. Moreover, the CPS system is used to improve product quality through the synchronization of CAD model inputs from the cloud platform. Therefore, the customer’s desired product will be available with minimum waste, less human monitoring, and less human interaction. The system contributes to the insight of developing a cloud-based digitized, automatic, remote system merging Industry 4.0 technologies to bring flexibility, agility, and automation to AM processes.