Industry 4.0 and Smart Systems in Manufacturing: Guidelines for the Implementation of a Smart Statistical Process Control

TLDR

Digital transformations in manufacturing enhance competitiveness by reducing costs, improving quality, and fostering innovation under Industry 4.0. The study provides a framework to integrate smart statistical digital systems into existing manufacturing control systems, guiding the transformation of traditional statistical process control into a smart version. Using design‑science research, the authors conducted a literature review and expert interviews to evaluate the proposed framework. The authors deliver general‑purpose guidelines that help manufacturers adopt smart technologies, serve as a roadmap for project management, and enable open‑innovation initiatives by breaking projects into defined steps.

Abstract

Digital transformations in manufacturing systems confer advantages for enhancing competitiveness and ensuring the survival of companies by reducing operating costs, improving quality, and fostering innovation, falling within the overarching umbrella of Industry 4.0. This study aims to provide a framework for the integration of smart statistical digital systems into existing manufacturing control systems, exemplified with guidelines to transform an existent statistical process control into a smart statistical process control. Employing the design science research method, the research techniques include a literature review and interviews with experts who critically evaluated the proposed framework. The primary contribution lies in a set of general-purpose guidelines tailored to assist practitioners in manufacturing systems with the implementation of digital, smart technologies aligned with the principles of Industry 4.0. The resulting guidelines specifically target existing manufacturing plants seeking to adopt new technologies to maintain competitiveness. The main implication of the study is that practitioners can utilize the guidelines as a roadmap for the ongoing development and implementation of project management. Furthermore, the study paves the way for open innovation initiatives by breaking down the project into defined steps and encouraging individual or collective open contributions, which consolidates the practice of open innovation in manufacturing systems.