Several high-tech manufacturing technologies are emerging to meet the demand for mass customized products. These technologies include configurable robots, augmented reality and the Internet-of-Things. Manufacturing enterprises can leverage these new technologies to pursue increased flexibility, i.e., the ability to perform a larger variety of activities within a shorter time. However, the flexibility offered by these new technologies is not fully exploited, because current operations management techniques are not dynamic enough to support high variability and frequent change. The HORSE Project investigated several of the new technologies to find novel ways to improve flexibility, as part of the Horizon 2020 research and innovation program. The purpose of the project was to develop a system, integrating these new technologies, to support efficient and flexible manufacturing. This article presents the core result of the project: a reference architecture for a manufacturing operations management system. It is based on the application and extension of business process management (BPM) to manage dynamic manufacturing processes. It is argued that BPM can complement current operations management techniques by acting as an orchestrator in manufacturing processes augmented by smart technologies. Building on well-known information systems’ architecting frameworks, design science research is performed to determine how BPM can be applied and adapted in smart manufacturing operations. The resulting reference architecture is realized in a concrete HORSE system and deployed and evaluated in ten practical cases, of which one is discussed in detail. It is shown that the developed system can flexibly orchestrate the manufacturing process through vertical control of all agents, and dynamic allocation of agents in the manufacturing process. Based on that, we conclude that BPM can be applied to overcome some of the obstacles toward increased flexibility and smart manufacturing.

Industry 4.0 is expected to deliver significant gains in productivity by assimilating several technological advancements including cloud computing, the Internet-of-Things, and smart devices. However, it is unclear how these technologies should be leveraged together to deliver the promised benefits. We present the architecture design of an information system that integrates these technologies to support hybrid manufacturing processes, i.e., processes in which human and robotic workers collaborate. We show how well-structured architecture design is the basis for a modular, complex cyber-physical system that provides horizontal, cross-functional manufacturing process management and vertical control of heterogenous work cells. The modular nature allows the extensible cloud support enhancing its accessibility to small and medium enterprises. The information system is designed as part of the HORSE Project: a five-year research and innovation project aimed at making recent technological advancements more accessible to small and medium manufacturing enterprises. The project consortium includes 10 factories to represent the typical problems encountered on the factory floor and provide real-world environments to test and evaluate the developed information system. The resulting information system architecture model is proposed as a reference architecture for a manufacturing operations management system for Industry 4.0. As a reference architecture, it serves two purposes: (1) it frames the scientific inquiry and advancement of information systems for Industry 4.0 and (2) it can be used as a template to develop commercial-grade manufacturing applications for Industry 4.0.

Business process management is often deployed to improve enterprise integration, but its impact is yet to reach manufacturing operations. We propose the concept of unified process management that facilitates integration between business management and manufacturing operations. The proposition is presented as an updated enterprise architecture for computer integrated manufacturing, converged around a centralized process management system. The process management system can orchestrate both business and operations activities by issuing work items to humans and robots connected via the internet-of-things. We present a realization of such a process management system and evaluate the proposition with an industrial case study. The results support the unification of process management as an enabler of smart manufacturing.