International Journal of Production Research

ISSN: (Print) (Online) Journal homepage: https://www.tandfonline.com/loi/tprs20

Machine learning in manufacturing and industry

4.0 applications

Rahul Rai, Manoj Kumar Tiwari, Dmitry Ivanov & Alexandre Dolgui

To cite this article: Rahul Rai, Manoj Kumar Tiwari, Dmitry Ivanov & Alexandre Dolgui (2021)
Machine learning in manufacturing and industry 4.0 applications, International Journal of
Production Research, 59:16, 4773-4778, DOI: 10.1080/00207543.2021.1956675

To link to this article: https://doi.org/10.1080/00207543.2021.1956675

Published online: 14 Aug 2021.

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INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH
2021, VOL. 59, NO. 16, 4773–4778
https://doi.org/10.1080/00207543.2021.1956675

EDITORIAL

Machine learning in manufacturing and industry 4.0 applications

Rahul Raia , Manoj Kumar Tiwarib , Dmitry Ivanovc and Alexandre Dolguid
a GRAIL Lab, Clemson University, Clemson, South Carolina; b Indian Institute of Technology, Kharagpur, India; c Hochschule für Wirtschaft und

Recht, Berlin, Germany; d IMT Atlantique, Nantes, France

ABSTRACT KEYWORDS
The machine learning (ML) field has deeply impacted the manufacturing industry in the context machine learning; industry
of the Industry 4.0 paradigm. The industry 4.0 paradigm encourages the usage of smart sensors, 4.0; manufacturing analytics;
devices, and machines, to enable smart factories that continuously collect data pertaining to pro- big data in manufacturing;
duction. ML techniques enable the generation of actionable intelligence by processing the collected cloud manufacturing; fault
detection
data to increase manufacturing efficiency without significantly changing the required resources.
Additionally, the ability of ML techniques to provide predictive insights has enabled discerning com-
plex manufacturing patterns and offers a pathway for an intelligent decision support system in a
variety of manufacturing tasks such as intelligent and continuous inspection, predictive mainte-
nance, quality improvement, process optimisation, supply chain management, and task scheduling.
While different ML techniques have been used in a variety of manufacturing applications in the
past, many open questions and challenges remain, from Big data curation, storage, and understand-
ing, data reasoning to enable real-time actionable intelligence to topics such as edge computing
and cybersecurity aspects of smart manufacturing. Hence, this special issue is focused on bring-
ing together a wide range of researchers to report the latest efforts in the fundamental theoretical
as well as experimental aspects of ML and their applications in manufacturing and production
systems.

Introduction
Manufacturing can be defined as the fabrication or
assembly of components into finished products on a
large scale (Encyclopaedia Britannica 2020). It is one of
the most important industries in the world’s economy
wherein, it accounts for approximately 16% of the global
GDP in 2019 and has generated an output of 13.9 trillion
globally (Sodani 2021). One of the most critical manu-
facturing goals is to produce more high quality products
at minimum costs. But manufacturing products can be
a very expensive and complicated process for businesses
that do not have the associated resources and tools to
design and develop quality products (AMFG AI 2019).
Over the last couple of centuries, the history of man-
ufacturing has changed dramatically. Instead of items
being produced using manual labour, industries sought
machines in order to produce the items, leading to the
Industrial Revolution in the 18th century. As of 2016, the
world entered the fourth Industrial Revolution coined
as ‘Industry 4.0’, which promotes the computerisation
of manufacturing by encompassing three technological
trends: connectivity, intelligence, and flexible automation
(AMFG AI 2019).
Industry 4.0 has given rise to an emerging sector in
manufacturing called Smart Manufacturing that opens
doors for analytics in the industry. Figure 1 represents
the various components attributed within the domain of
Smart Manufacturing (Sodani 2021). It is a technology-
driven approach that utilises the IoT and internet-
connected devices to produce goods and monitor pro-
cesses. Its goal is to automate the processes involved in
manufacturing to maximise efficiency, increase sustain-
ability, supply chain management, and identify the sys-
tems barriers even before they occur by generating, opti-
mising, and implementing enormous volumes of data.
With the application of advanced analytics to industrial
data, manufacturers can gain insights to optimise the
productivity of individual assets as well as the total man-
ufacturing operation prevailing artificial intelligence (AI)
and machine learning (ML).
Industry 4.0 converges information technology and
operational technology to create a cyber-physical

CONTACT rrai@clemson.edu
© 2021 Informa UK Limited, trading as Taylor & Francis Group
4774 EDITORIAL

subset of the Internet of Things (IoT) which refers to a

Figure 1. Global Smart Manufacturing Segmentation.
Figure 2. The multi-faceted usage of AI and machine learning in
manufacturing domain.
environment with digital solutions and advanced tech-
nologies including,
network of physical devices that are digitally intercon-
nected, facilitating the communication and exchange of
data through the internet IIoT interconnects machines
through various sensors, RFID tags, software, and elec-
tronics which are integrated with machines to collect
real-time data. The abundance of smart sensors and
the Internet of Things are the key enabler of curating
and storing a remarkable amount of industrial data-
rich environments related to all aspects of production.
Digital twin runs an online simulation based on data
received from IIoT. A digital twin is a digital repre-
sentation of a real-world product, machine, process,
or system that allows companies to better understand,
analyise and optimise their processes through real-time
simulations.
Cloud computing uses internet connections to store,
access, and process data and is a key enabler of the digital
twin paradigm. Additionally, current generation manu-
facturing is supported by advanced technologies such as
advanced robotics, augmented, and virtual reality and
additive manufacturing. ML techniques, a subfield of
Artificial Intelligence (AI), has the potential to become
the main driver in uncovering fine-grained intricate pro-
duction patterns in smart manufacturing paradigm and
offering timely decision support in a wide range of
manufacturing and production applications, to name a
few, predictive maintenance, process optimisation, task
scheduling, quality improvement, supply chain, and sus-
tainability so on.
Smart use of technology and AI can help grow and
drive businesses. The biggest companies around the
world are utilising AI and ML in manufacturing and
investing huge amounts of money in its development
(Chuprina 2020). According to Mckinsey 40% of all the
potential value that can be created by analytics today,
comes from AI and ML techniques, wherein ML accounts
for between $3.5 trillion to $5.8 trillion in annual value.
Data-driven techniques automate learning from data,
detect prevalent underlying patterns and make informed
decisions. Industries have been successful in the applica-
tion of machine learning mainly into three aspects of the
business:

• Industrial Internet of Things (IIoT) • Additive manufacturing (AM) • Operations • Productions • Post-Productions
• Digital twin • Advanced robotics
• Cloud computing • Augmented and virtual reality
Additionally, data analytics in the manufacturing
In manufacturing, a paradigm shift is happening right industry can be used to amplify growth in the following
now. Advances in Big data and Machine Learning (ML) domains (but not limited to)
is changing the traditional manufacturing era into the
smart manufacturing era of Industry 4.0 (I4.0). This (1) Improve assembly-line efficiency using data
paradigm shift is creating new opportunities. IIoT is a analytics.

(2) Improved Customer Experience, including
personalisation and finding individualised value
propositions.
(3) Inventory management by
(a) Real-time insights and visibility into inventory
along the supply lines
(b) Delivery route optimizations
(4) Minimise loss associated with delayed, damaged, or
lost goods in transport and for providing real-time
asset management include real-time alerts
(5) Reduce errors and corrections during product devel-
opment and improve the product’s quality and pack-
aging with,
(a) Analytics-backed simulations
(b) Product modelling
(6) Predictive maintenance helps increase assets’ life-
time by,
(a) Asset Management.
(b) Improving asset availability.
(c) Detection of faults and defects.
(d) Prevention of unplanned downtimes.
(7) Increase visibility into the supply chain with action-
able data location-based IoT services.
The manufacturing environment offers enormous oppor-
tunities to leverage artificial intelligence techniques for
better decision-making (Sharma, Zhang, and Rai 2021).
A key enabler of AI in manufacturing environments is
IIoT, which facilitated the harnessing of big data. Big
data, in turn, needs AI to make decisions in real-time.
The core techniques of AI like deep learning, computer
vision, reinforcement learning have already been utilised
in manufacturing scenarios. Computer vision has been
leveraged for structural health monitoring (Yang et al.
2020). The vision-based techniques offered high spatial
resolution even with inexpensive sensors. Ontology can
be used to store and organise the knowledge of manufac-
turing systems (Ali et al. 2019). AI can be used to study
the brain computer interface of manufacturing opera-
tors (Shankar and Rai 2014). This can enhance the study
of industrial safety and ergonomics. The data generated
by manufacturing processes, like additive manufacturing,
can be analyised for real-time monitoring, control, and
defect minimisation (Khadilkar, Wang, and Rai 2019).
The manufacturing equipment can be diagnosed and
prognosed using machine learning (Yang and Rai 2019).
Augmented reality devices have been used for mainte-
nance applications (Young and Rai 2021). They offered
additional flexibility to reconfigure the maintenance pro-
cedure on the go.
While different ML techniques have been used in a
variety of manufacturing applications in the past, many
open questions and challenges remain, from Big data
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH 4775
curation, storage, and understanding, data reasoning to
enable real-time actionable intelligence to advanced top-
ics such as edge computing, fog computing, cybersecurity
aspects of smart manufacturing. Hence, this special issue
is focused on bringing together a wide range of researchers
to report the latest efforts in the fundamental theoretical as
well as experimental aspects of ML and their applications
in manufacturing and production systems.
Summary of papers in this special issue
A summary of papers that address several important
issues at the intersection of manufacturing and ML
domain is presented next. Different categories to which
the papers belong and the importance of these categories
in machine learning in the manufacturing context are
elaborated next.
Computer vision-based inspection and monitoring
One of machine learning’s most high-impact application
areas in the manufacturing domain is computer vision-
based part inspection and process monitoring. Utilising
cost-effective sensors such as RGB cameras wrapped with
ML-based algorithms can enable high throughput part
inspection. Computer vision (images and video) based
approaches that are integrated with ML can enable moni-
toring of a product throughout the entire production pro-
cess. Additionally, a computer vision-based approach can
also enable high-quality continuous process monitoring.
‘A data-driven method for Enhancing the image-
based automatic inspection of IC wire bonding defects’
by Chen et al. (Chen, Zhang, and Wu 2020) offers a
data-driven method for enabling automatic inspection
of integrated circuit (IC) wire bonding defects. The out-
lined method in the paper comprises of three steps: (1)
data pre-processing for locating and separating IC chip
image patches from the raw image, (2) feature engineer-
ing that extracts geometric features from the segmented
wires, and (3) machine learning algorithms (such as CNN
and SVM) based classification. The authors showcase the
efficacy of the developed method on a set of X-ray images
collected from a semiconductor factory.
‘Soft sensor of flotation froth grade classification
based on hybrid deep neural network’ by Zhang and
Gao (Zhang and Gao 2021) summarises their efforts to
develop a soft sensor that can process froth images of
flotation tailing to classify iron ore tailings grade. The two
key contributions of the paper are to curate and establish
a database of froth images of flotation tailings and a com-
parison of the accuracy of multiple deep neural network
(DNN) models for the task at hand. Based on the com-
parison results, the authors outline a fine-tuned hybrid
4776 EDITORIAL

DNN model that has excellent accuracy and develops machine learning-based manufacturing solutions at scale
software around it. The experimental results show the will be key in the near future.
potential of application of DNNs in the field of iron ore ‘A cloud edge-based two-level hybrid scheduling
froth flotation. learning model in cloud manufacturing’ by Jian et al.
(Jian, Ping, and Zhang 2020) presents a cloud edge-based
two-level hybrid scheduling learning model to enable fast
Fault detection prediction of the scheduling results. The proposed model
at the first level decomposes and distributes multiple
Timely and accurate diagnosis of manufacturing equip-
scheduling tasks into several first-level sub-tasks based
ment process faults provides a strategic advantage to help
on First-in First-out (FIFO) principle. The second level
manufacturing companies stay competitive by reduc-
enables even granular decomposition to atomic tasks that
ing machine downtimes. Machine learning algorithms
are then scheduled to different industrial devices (factory
within the manufacturing industry will find increased
edge nodes). The second level utilises an innovative com-
usage for enabling manufacturing system fault diagno-
bination of improved bat algorithm (VSSBA) and long
sis as more and more customers require manufacturers
and short-term memory networks (LSTM) for schedul-
to expedite the delivery of high-quality products at a low
ing problems. Experiments performed by the authors
cost.
show that the two-level approach can improve perfor-
‘A deformable CNN-DLSTM based transfer learning
mance in real-life applications in a cloud manufacturing
method for fault diagnosis of rolling bearing under multi-
setting.
ple working conditions’ by Wang et al. (Wang et al. 2020)
presents a transfer learning-based approach that com-
bines deformable convolutional neural network (CNN) Process improvement and optimisation
and deep long short-term memory (DLSTM) rolling
The prescriptive analytics power of ML techniques can
bearing fault diagnosis. The authors specifically focus on
augment the manufacturing employees’ effort to select
bearing faults under multiple working conditions where
the optimal set of parameters related to a given man-
it is hard to find sufficiently large-scale labelled data. The
ufacturing process, hence enabling manufacturing pro-
transfer learning approach allows them to pre-train fault
cess improvement and optimisation. The discipline at the
diagnosis model using data samples under one working
intersection of ML and process improvement that leads
condition and then transfer the model with further fine-
to manufacturing analytics insights enabling faster mass
tuning (with very few data samples) to another working
and customised production at a rapid pace with as little
condition. The developed framework, when applied to
waste as possible will grow by leaps and bound in the next
an experimental data set, shows better results than the
decade.
state-of-the-art methods.
‘An investigation of the utilisation of different data
‘Applications of deep learning for fault detection in
sources in manufacturing with application in Injection
industrial cold forging’ by Glaeser et al. (Glaeser et al.
Moulding’ by Rønsch et al. (Rønsch, Kulahci, and Dyb-
2021) showcase the usage of deep learning techniques in
dahl 2021) report their work on the study that explores
the industrial cold forging fault detection domain. Specif-
effective utilisation of various data sources for process
ically, the authors outline two different approaches based
improvement in injection moulding. Specifically, the
on convolutions neural network (CNN) and decision
authors investigate whether a good prediction accuracy
tree (DT) to understand how machine signal impacted
can be achieved by using readily available Machine Pro-
various faults. The outlined approaches show superior
cess Data on a moulding manufacturing line comprising
performance on vibration test data sets collected for com-
of 100 injection moulding machines or additional sensor
monly encountered faults in the industrial cold forging
signals obtained at a higher cost can provide additional
domain.
beneficial information. For the specific use case that was
carried out in close collaboration with an industrial part-
ner, they conclude that available machine process data
Cloud manufacturing
does not capture the variation in the raw material that
Cloud storage within manufacturing is being embraced impacts element quality.
to store and manage manufacturing production big data. ‘Using process mining to improve productivity in
Aside from the understandably increased storage space, make-to-stock manufacturing’ by Lorenz et al. (Lorenz
the cloud and machine learning techniques will help et al. 2021) demonstrate a novel use case of data-
reduce costs and drive profitability. Understanding how driven procedure to improve productivity in make-to-
hardware – Edge vs Cloud – in deploying real-world stock manufacturing. Specifically, the outlined procedure

utilises process mining to dynamically map and analyse
manufacturing processes with high process complexity
and variety in an automated manner to enable produc-
tivity improvement. The authors also empirically validate
the usage of the developed procedure on a test case ema-
nating from a leading manufacturer of sanitary products
and provide tangible improvement suggestions for the
manufacturers.
‘A supervised machine learning approach for the
optimisation of the assembly line feeding mode selec-
tion’ by Zangaro et al. (Zangaro, Minner, and Battini
2020) outlines a supervised learning-based approach
that utilises classification and regression tree (CART)
algorithm for line feeding problem (LFP). The proposed
approach takes as input attributes of components and
manufacturing environment to create a decision tree that
suggests a line feeding mode for every component. Addi-
tionally, for cases that result in an infeasible solution,
they also outline a repair approach that provides feasi-
ble solutions with respectable average cost deviation. The
proposed approach predicts line feeding mode with good
classification accuracy.
State of the art review papers
Review papers related to machine learning applications
in the manufacturing domain in this special issue bring
together quantitative and qualitative components and
provide new conceptual frameworks, synthesise diverse
results, and give the broader research community a ‘state-
of-the-art’ snapshot of essential issues related to the focus
of this special issue.
‘Artificial intelligence (AI) in augmented reality (AR)-
assisted manufacturing applications: a review’ by Sahu
et al. (Sahu, Young, and Rai 2020) provides a compre-
hensive review of a very dynamic research domain at
the intersection of AI and AR. The current paradigms
utilised in AR for camera calibration, detection, track-
ing, camera position and orientation (pose) estimation,
inverse rendering, procedure storage, virtual object cre-
ation, registration, and rendering are still mostly domi-
nated by traditional non-AI approaches. The authors pro-
vide a critical appraisal of these strategies. Additionally,
the authors also outline potential AI solutions for every
component of the computational pipeline. Furthermore,
interesting and fruitful future research work directions at
the intersection of AI and AR are also listed.
‘The interpretive model of manufacturing: A theoret-
ical framework and research agenda for machine learn-
ing in manufacturing’ by Sharma et al. (Sharma, Zhang,
and Rai 2021) argues that a new framework is needed
to fully comprehend the paradigm of application of
machine learning in manufacturing. The authors present
INTERNATIONAL JOURNAL OF PRODUCTION RESEARCH 4777
a comprehensive hybrid literature review approach
comprising of a thematic and conceptual synthesis of the
literature resulting in the interpretive model framework
of manufacturing. The resultant interpretative frame-
work is articulated as consisting of scan, store, interpret,
execute, and learn as its purposive components. Addi-
tionally, the authors provide pertinent future research
questions and implications for manufacturing opera-
tions, manufacturing strategy, and manufacturing.
Conclusion
Manufacturing is undertaking a definitive shift as it
assimilates and is transformed by the usage of machine
learning techniques. This special issue brought together
a wide range of researchers to report the latest efforts
in the fundamental theoretical as well as experimental
aspects of ML and their applications in manufacturing
and production systems to understand and contextualise
this shift at the onset of this decade. The topics such
as computer-vision based inspection and monitoring,
fault detection, cloud manufacturing, process improve-
ment and optimisation, and comprehensive state of the
art review papers are spanned by the papers in this special
issue.
Going forward, as Industry 4.0 transforms the man-
ufacturing environments into cyber-physical environ-
ments, AI will be indispensable for data analysis and
subsequent decision-making (Rai and Sahu 2020). Prod-
uct design (Huang and Rai 2018), inspection (Zhang et al.
2019a), geometry processing (Zhang, Jaiswal, and Rai
2018), material informatics (Wang et al. 2021), control
of dynamic systems (Zhang et al. 2021) are few more
applications of ML in manufacturing. The utility of ML
in manufacturing applications reflects that ML can be
integrated into every phase of product lifecycle, starting
from design to disposal of the product in a manufacturing
environment.
It is also important to note that the ML-based
decision-making in manufacturing applications can also
be supplemented by the physics governing the physical
phenomena. Synergizing ML with physics becomes cru-
cial, especially in the case of manufacturing applications
where data generation can be expensive and unsafe (Rai
and Sahu 2020).
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