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This study aims to discuss the state-of-the-art digital factory (DF) development combining digital twins (DTs), sensing devices, laser additive manufacturing (LAM) and subtractive manufacturing (SM) processes. The current shortcomings and outlook of the DF also have been highlighted. A DF is a state-of-the-art manufacturing facility that uses innovative technologies, including automation, artificial intelligence (AI), the Internet of Things, additive manufacturing (AM), SM, hybrid manufacturing (HM), sensors for real-time feedback and control, and a DT, to streamline and improve manufacturing operations.

This study presents a novel perspective on DF development using laser-based AM, SM, sensors and DTs. Recent developments in laser-based AM, SM, sensors and DTs have been compiled. This study has been developed using systematic reviews and meta-analyses (PRISMA) guidelines, discussing literature on the DTs for laser-based AM, particularly laser powder bed fusion and direct energy deposition, in-situ monitoring and control equipment, SM and HM. The principal goal of this study is to highlight the aspects of DF and its development using existing techniques.

A comprehensive literature review finds a substantial lack of complete techniques that incorporate cyber-physical systems, advanced data analytics, AI, standardized interoperability, human–machine cooperation and scalable adaptability. The suggested DF effectively fills this void by integrating cyber-physical system components, including DT, AM, SM and sensors into the manufacturing process. Using sophisticated data analytics and AI algorithms, the DF facilitates real-time data analysis, predictive maintenance, quality control and optimal resource allocation. In addition, the suggested DF ensures interoperability between diverse devices and systems by emphasizing standardized communication protocols and interfaces. The modular and adaptable architecture of the DF enables scalability and adaptation, allowing for rapid reaction to market conditions.

Based on the need of DF, this review presents a comprehensive approach to DF development using DTs, sensing devices, LAM and SM processes and provides current progress in this domain.

A Digital Twin (DT) is a digital replica of an artefact which is updated on real-time or semi–real-time basis. In 2017, Gartner listed DT as one of the top 10 emerging technologies of the year. Since then, there have been numerous attempts to develop architecture and reference models for DTs, and in some studies, DT construction for real-world case studies is reported. This chapter attempts to provide a contextualised background on DT for smart cities. It also discusses various stakeholders involved in devising and/or employing DTs in a smart city. The chapter concludes with a set of recommendations for the training requirements of final DT users.

The purpose of this paper is to design and manufacture an intelligent 3D printed sensor to monitor the re-occurrence of diaphragmatic hernia (DH; after surgery) in bovines as an Internet of Things (IOT)-based solution.

The approach used in this study is based on a bibliographic analysis for the re-occurrence of DH in the bovine after surgery. Using SolidWorks and ANSYS, the computer-aided design model of the implant was 3D printed based on literature and discussions on surgical techniques with a veterinarian. To ensure the error-proof design, load test and strain–stress rate analyses with boundary distortion have been carried out for the implant sub-assembly.

An innovative IOT-based additive manufacturing solution has been presented for the construction of a mesh-type sensor (for the health monitoring of bovine after surgery).

An innovative mesh-type sensor has been fabricated by integration of metal and polymer 3D printing (comprising 17–4 precipitate hardened stainless steel and polyvinylidene fluoride-hydroxyapatite-chitosan) without sacrificing strength and specific absorption ratio value.

Surface acoustic wave (SAW) sensors have attracted great attention worldwide for a variety of applications in measuring physical, chemical and biological parameters. However, stability has been one of the key issues which have limited their effective commercial applications. To fully understand this challenge of operation stability, this paper aims to systematically review mechanisms, stability issues and future challenges of SAW sensors for various applications.

This review paper starts with different types of SAWs, advantages and disadvantages of different types of SAW sensors and then the stability issues of SAW sensors. Subsequently, recent efforts made by researchers for improving working stability of SAW sensors are reviewed. Finally, it discusses the existing challenges and future prospects of SAW sensors in the rapidly growing Internet of Things-enabled application market.

A large number of scientific articles related to SAW technologies were found, and a number of opportunities for future researchers were identified. Over the past 20 years, SAW-related research has gained a growing interest of researchers. SAW sensors have attracted more and more researchers worldwide over the years, but the research topics of SAW sensor stability only own an extremely poor percentage in the total researc topics of SAWs or SAW sensors.

Although SAW sensors have been attracting researchers worldwide for decades, researchers mainly focused on the new materials and design strategies for SAW sensors to achieve good sensitivity and selectivity, and little work can be found on the stability issues of SAW sensors, which are so important for SAW sensor industries and one of the key factors to be mature products. Therefore, this paper systematically reviewed the SAW sensors from their fundamental mechanisms to stability issues and indicated their future challenges for various applications.

The purpose of this paper is to investigate the relationships between augmented reality, process innovativeness and operational performance.

This research is based on a quantitative approach using a questionnaire survey from a total of 117 firms in the automotive sector. The hypothesized relationships are tested using partial least square structural equation modeling (PLS-SEM).

This study demonstrates that augmented reality is positively associated with process innovativeness, and process innovativeness is positively related to operational performance. Furthermore, it is found that process innovativeness fully mediates the relationship between augmented reality and operational performance.

Although augmented reality attracts great attention from academics and practitioners, the current literature lacks an empirical investigation on how augmented reality creates value for the business. Addressing this crucial gap, this research is the first attempt to empirically reveal the role of augmented reality in facilitating process innovativeness and also unearthing how augmented reality improves operational performance. Therefore, this study offers novel insights into the role of augmented reality in business and provides theoretical and managerial contributions.

This study aims to provide a bibliometric analysis and systematic literature review of Industry 4.0 (I4.0) research in the supply chain (SC) area and to understand related contemporary research trends. I4.0 has the potential to change the way goods are manufactured, distributed and made available to customers through the digitalisation of SC. Although I4.0 originated in 2011 in Germany, its application in managing the SC has only recently started gaining momentum. Therefore, it is essential to understand the research progress and identify the current trends of I4.0 application in the SC field.

A bibliometric analysis was conducted to empirically analyse the literature related to I4.0 implementation in the SC. This study retrieved papers from the Scopus database, reviewing 1,155 articles from the period 2016 to 2023 (November) for bibliometric analysis. Bibliometrix, using R software, was used for the bibliometric analysis, and VOSviewer was used for network analysis.

The findings provide an overview of the most relevant journals, most productive scholars, top academic institutions and top countries contributing to I4.0 research in the SC context. The results show that the most recent research contributions are related to the topics of SC performance, sustainability, digitalisation and digital transformation. Furthermore, a detailed review of articles published in the three and above-rated journals in the Chartered Association of Business Schools list is presented.

The novelty of this study lies in identifying the current research trends and themes of I4.0 research in the SC area. This research benefits researchers by identifying potential research areas for I4.0 implementation in the SC and providing directions for future research.

Industry 4.0 has put forward a smart perspective on managing supply chain networks and their operations. The current manufacturing system is primarily data-driven. Industries are deploying new emerging technologies in their operations to build a competitive edge in the business environment; however, the true potential of smart manufacturing has not yet been fully unveiled. This research aims to extensively analyse emerging technologies and their interconnection with smart manufacturing in developing smarter supply chains.

This research endeavours to establish a conceptual framework for a smart supply chain. A real case study on a smart factory is conducted to demonstrate the validity of this framework for building smarter supply chains. A comparative analysis is carried out between conventional and smart supply chains to ascertain the advantages of smart supply chains. In addition, a thorough investigation of the several factors needed to transition from smart to smarter supply chains is undertaken.

The integration of smart technology exemplifies the ability to improve the efficiency of supply chain operations. Research findings indicate that transitioning to a smart factory radically enhances productivity, quality assurance, data privacy and labour efficiency. The outcomes of this research will help academic and industrial sectors critically comprehend technological breakthroughs and their applications in smart supply chains.

This study highlights the implications of incorporating smart technologies into supply chain operations, specifically in smart purchasing, smart factory operations, smart warehousing and smart customer performance. A paradigm transition from conventional, smart to smarter supply chains offers a comprehensive perspective on the evolving dynamics in automation, optimisation and manufacturing technology domains, ultimately leading to the emergence of Industry 5.0.

This study aims to comparatively analyze the cut parts obtained as a result of cutting the Ni-based Inconel 625 alloy, which is widely used in the aerospace industry, with the wire electro-discharge machining (WEDM) and abrasive water jet machining (AWJM) methods in terms of macro- and microanalyses.

In this study, calipers, Mitutoyo SJ-210, Nikon SMZ 745 T, scanning electron microscope and energy dispersive X-ray were used to determine kerf, surface roughness and macro- and microanalyses.

Considering the applications in the turbine industry, it has been determined that the WEDM method is suitable to meet the standards for the machinability of Inconel 625 alloy. In contrast, the AWJM method does not meet the standards. Namely, while the kerf angle was formed because the hole entrance diameters of the holes obtained with AWJM were larger than the hole exit diameters, the equalization of the hole entry and exit dimensions, thanks to the perpendicularity and tension sensitivity of the wire electrode used in the holes drilled with WEDM ensured that the kerf angle was not formed.

It is known that the surface roughness of the parts used in the turbine industry is accepted at Ra = 0.8 µm. In this study, the average roughness value obtained from the successful drilling of Inconel 625 alloy with the WEDM method was 0.799 µm, and the kerf angle was obtained as zero. In the cuts made with the AWJM method, thermal effects such as debris, microcracks and melted materials were not observed; an average surface roughness of 2.293 µm and a kerf of 0.976° were obtained.

This study aims to investigate the corrosion behavior of stir-cast hybrid aluminum composite reinforced with CeO₂ and graphene nanoplatelets (GNPs) nanoparticulates used as cylinder liner material in the engines (automotive, aerospace and aircraft industries).

The composites were prepared using the stir-casting technique, and their microstructure and corrosion behavior was evaluated using scanning electron microscopy (SEM) and potentiodynamic polarization test, respectively.

The results showed that the addition of CeO₂ and GNPs improved the corrosion resistance of the composites, and the optimal combination of these two nanoparticles was found to be 3 wt.% CeO₂ and 3 wt.% GNPs. The enhanced corrosion resistance was attributed to the formation of a protective layer on the surface of the composite, as well as the effective dispersion and uniform distribution of nanoparticles in the matrix. The 0.031362 was noted as the lowest corrosion rate (mmpy) and was noticed in 94% Al-6061 alloy + (3 Wt.% CeO₂ + 3 Wt.% GNPs) sample at room temperature and at elevated temperatures; the corrosion rate (mmpy) was observed as 0.0601 and 0.0636 at 45 °C and 75 °C, respectively.

In the vast majority of the published research publications, either cerium oxide or graphene nanoplatelets were utilized as a single reinforcement or in conjunction with other types of reinforcement such as alumina, silicon carbide, carbon nano-tubes, tungsten carbide, etc., but on the combination of the CeO₂ and GNPs as reinforcements have very less literatures with 2 wt.% each only. The prepared hybrid aluminum composite (reinforcing 1 wt.% to 3 wt.% in Al-6061 alloy) was considered for replacing the cylinder liner material in the piston-cylinder arrangement of engines.

Industry 4.0-driven digitalisation is said to offer a way to redesign traditional compliance-oriented quality management (QM) models. However, despite a rising academic and practitioner interest, it is still unclear how companies transform their current QM models to meet the real-time needs of the new manufacturing paradigm. The purpose of this study is to explore practices for the digitalisation of QM and to uncover the digitalisation journey.

An exploratory research approach of an embedded case study of a multinational auto-component manufacturer was adopted to achieve the research aim.

A guiding framework called the “Quality 4.0 transition framework” was developed based on literature and expert knowledge. The framework is made up of three building blocks, i.e. the foundation of “as-is” digitalisation maturity assessment; pillars representing horizontally and vertically integrated QM processes, and roof signifying reinforcement of total quality management (TQM) principles at all levels.

The study provides empirical evidence of the case company's digitalisation journey to avert product recall due to field failure issues. The study contributes to theory and practice in many ways. First, the study uses empirical data from a real-world case to understand how digitalisation affects QM processes. Next, the guiding framework for the Quality 4.0 transition adds to the existing literature on the digitalisation of business processes.