Smart Factories in the Era of Industry 4.0: Convergence of IoT and Cyber-Physical Systems for Intelligent Automation, Connectivity, and Resilient Manufacturing

DOI

10.2991/978-94-6463-914-8_17How to use a DOI?

Keywords

Industry 4.0; Smart Manufacturing; Cyber-Physical Systems; Internet of Things; Intelligent Automation; Digital Twin; Predictive Maintenance

Abstract

The convergence of Internet of Things (IoT) and Cyber-Physical Systems (CPS) represents a transformative paradigm in modern manufacturing, establishing the foundation for Industry 4.0 smart factories. This paper presents a comprehensive framework for intelligent automation that integrates real-time data acquisition, predictive analytics, and adaptive control mechanisms to enhance manufacturing efficiency and resilience. We propose a hierarchical architecture comprising five interconnected layers addressing sensing and actuation, edge computing, fog computing, cloud analytics, and enterprise integration. Our framework addresses critical challenges including interoperability, security, scalability, and real-time decision-making. Through simulation studies and theoretical analysis using real-world manufacturing datasets totaling over 10 million data points, we demonstrate that the proposed framework achieves 34% improvement in Overall Equipment Effectiveness (OEE), 42% reduction in unplanned downtime, and 28% enhancement in energy efficiency compared to traditional manufacturing systems. The research contributes a novel multi-agent coordination protocol employing game-theoretic consensus mechanisms for distributed manufacturing environments and introduces adaptive ensemble machine learning algorithms achieving 94.8% accuracy in predictive maintenance. Implementation considerations, including comprehensive cybersecurity measures and standardization requirements, are thoroughly examined to facilitate practical deployment in industrial settings.

Copyright

© 2025 The Author(s)

Open Access

Open Access This chapter is licensed under the terms of the Creative Commons Attribution-NonCommercial 4.0 International License (http://creativecommons.org/licenses/by-nc/4.0/), which permits any noncommercial use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license and indicate if changes were made.

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TY  - CONF
AU  - K. P. Arjun
AU  - V. Smitha
PY  - 2025
DA  - 2025/12/24
TI  - Smart Factories in the Era of Industry 4.0: Convergence of IoT and Cyber-Physical Systems for Intelligent Automation, Connectivity, and Resilient Manufacturing
BT  - Proceedings of the International Conference on Operations & Supply Chain Management 2025 (ICOSCM 2025)
PB  - Atlantis Press
SP  - 261
EP  - 270
SN  - 2352-5428
UR  - https://doi.org/10.2991/978-94-6463-914-8_17
DO  - 10.2991/978-94-6463-914-8_17
ID  - Arjun2025
ER  -