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Industry 4.0: A Comparative Analysis of Advanced Planning And Scheduling

Manufacturing Soft Wares For Implementation And Adoption In Connected
Factories

Conference Paper · September 2022

DOI: 10.1109/SmartNets55823.2022.9993991

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Queeneth Adesuwa Kingsley -Omoyibo Christopher Chukwutoo Ihueze

Igbinedion University Okada,Edo state,Nigeria Nnamdi Azikiwe University, Awka
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 Industry 4.0: A Comparative analysis of advanced planning and scheduling
manufacturing soft wares for implementation and adoption in connected
factories.

Kingsley-Omoyibo queeneth.omoyibo@iuokad Engineering cc.ihueze@unizik.edu.ng,

Queeneth Adesuwa, a-edu.ng ,+2348141391481 Nnamadi Azikiwe +2348037065761
Department of Mechanical University,
Engineering Ihueze Christopher Awka (UNIZIK)
Igbinedion University Chukwutoo Anambra State, Nigeria
Okada, Edo State, Nigeria Department of Industrial

ABSTRACT value of alpha at 0.98241 embracing the full package of the

The dire need to implement and adopt industry 4.0 in order to
stabilize supply chains, improve throughput in manufacturing
processes to meet planning and scheduling needs using advanced
planning and scheduling manufacturing software key enablers
such as production sequencing, real time optimization, planning
and scheduling, prompted this study. The aim of this study is to
comparatively analyze and select from the advanced
manufacturing software key enablers to be used to implement
and adopt industry 4.0 for a connected factory. The concurrent
triangulation design was used for analyzing the data collected
from industry survey questionnaires distributed. The internal
consistency of the respondents from the in-depth interview was
measured using reliability test results from cronbach alpha
values for production scheduling software, real time optimization
software, production planning software and production
sequencing software were 0.99147, 0.98814, 0.97910 and 0.97095
respectively using the rule of thumb 0≥ 0.9 excellent which
showed a good index of association. A total of 450 questionnaires
were distributed, retrieved and found useable. Results from
phase 1 and phase 2 of the concurrent triangulation model were
merged and showed that 33.78% industries were of the opinion
that optimizing supply network cost and implementing a
complete order allocation using production scheduling software
for Industry 4.0 will speedup implementation of connected
factories, 34.22% were in support of production planning,
17.33%were in support of real time optimization while
production sequencing and 14.67% supported production
sequencing manufacturing software. From the results, optimized
software used to implement and adopt industry 4.0for connected
factories, will help to keep pace with industry-leading digitization
practices when fully implemented and adopted.
Keywords:
Industry 4.0, connected factories, manufacturing software,
implementation, adoption, concurrent triangulation model.
1. INTRODUCTION
A categorical framework of manufacturing for Industry 4.0
and beyond was researched and showed that concepts emerged
and there was focus on fundamental conception of industry
4.0. It looked into the present state of manufacturing systems.
The implementation structures of industry 4.0 consist of multi-
layered framework. This framework showed how the
requirements of Industry 4.0 can be achieve [1].
Implementation of connected factories can be achieved using
agile processes, optimizing production through the
configuration of technologies that are considered modular and
ensuring that people are digitalized [2]. Product-Service-
Systems (PSS), a business model helps to provide cohesive
delivery of products and services to bring about pro-
environmental outcomes. It used a strategic approach to cover
the value proposition for the performances of a system
throughout product life cycle. This management approach was
changed to the Cyber-Physical-System (CPS) design for a real
industrial use towards industry 4.0. The cyber-physical system

978-1-6654-8758-0/22/$31.00 ©2022 IEEE

used engineered systems built seamless integration of
computational algorithms to produce Wireless Sensor
Networks (WSNs) [3]. Lean automation enabled by industry
4.0 technologies helped to minimize waste within
manufacturing systems and also helped to maximize
productivity. Lean automation in the research article of [4],
helped to specify value by defining value from product to
service, map the value stream, create flow, establish pull and
seek perfection to help build quality [4]. The production of
goods that are personalized helps manufacturing Industries to
build up competition with flexibility and digitization of these
products. This technique merges the physical with the digital
to step up planning process and optimization of manufacturing
systems. The use of cyber system on a large scale was
analyzed and presented [5]. Factories have become smart in
order to service the turbulence in production market hence
cyber-physical productions systems in connected factories
with real time, is a new era in Industrial manufacturing [6].
Industry 4.0 is a driver to manufacturing for a speedy change
in consumer trends for flexibility and adaption of achieving
economies of scale. Hence, collaboration mechanisms are
adapted in order to increase productivity in the context of
industries 4.0 [7]. All research issues in industry 4.0 have been
analyzed, looking into economic sides, business strategies,
models, it provided an overview of industries 4.0 and looked
into programs of connected manufacturing, looked at cyber-
physical-system (CPS) which dealt with product design and
intelligence in manufacturing. It looked into logistics and
issues in industries 4.0 in the Now and the future [8]. For the
Industry 4.0 revolution to be adopted and implemented [9]
looked into collaboration. The researcher studied the
collaborative maintenance in flow line manufacturing and
used the approach of Industry 4.0 technologies such as the
industrial internet of things (I io T) and Artificial intelligence
[9]. A critical review into industrial automation and robotics
was looked into [10]. Industrial process and machinery are
been replaced with robotics and automation for improved
efficiency, improved speed, quality and optimized
performances. Transforming the manufacturing space have
become exigent, hence the review [10]. Computerized systems
were used to aid manufacturing using the Manufacturing
Execution Systems (MES) in order to track products,
document manufacturing of raw materials from start to the
finish line using MES. It helped to improve production output
and all operation of manufacturing was effectively executed
[11]. The internet of things, Big Data in Industry 4.0 was
critically looked into [12]. Innovative solutions in logistics
and supply chain management was researched, flow of goods
being properly handled, and services of raw material handling
was looked into. The process of supply chain required a
network of suppliers serving as link in the supply chain to
move products from one stage of the chain to another through
planning, making, considering the source, delivering the
products and returning (Distribution) [12]. An article reviewed
the referenced architecture for Internet of things based on
connected factories and focused on the sustenance of these
factories. An approach to energy management was proposed
based on the paradigm of IoT with benefits discussed [13]. A
high class design for today’s factory is crucial. Hence [14]
looked into factory - of -things. Speeding up planning, that
adapts to operational product change to reduce efforts in
planning was researched. Smart technologies were used to
meet up with challenges of factories. The smart factory
initiative helped to create a demonstration test for new
solutions and gave an insight on various experiences gained
from the survey on smart factories for users of factories.
Cyber Physical System (CPS) based architecture was also
surveyed by [15]. The author looked into seamless algorithms
that were not stand-alone. The CPS used intelligent
manufacturing lines and instrumentation to solve factory
problems.
1.a Industries 4.0
Implementation of industry 4.0 in connected factories will
boost throughput and cater for bottlenecks. Industry 4.0
technologies such as cloud computing, cyber security, 3D
printing, Big Data, Robotics, Digital Twinning (simulation),
virtual reality (augmented reality) and Internet of things are
needed for a connected factory for productivity, automation
and data exchange in manufacturing technologies. This survey
looked into research gaps between industries 4.0 and
manufacturing systems in the area of implementation and
adoption and found out that industries 4.0 has not be fully
adopted and implemented in industries and has not become
real time response. Presently, manufacturing industries in
Nigeria are operating on flexible manufacturing system and
some others are on reconfigurable manufacturing system. Data
is collected from sensors and production lines are strictly
monitored. Supply chain in the area of goods flowing from
wholesalers to retailers with proper management, proper
planning and effective distribution if monitored will boost
logistics. The implementation and adoption of advanced
production planning, production sequencing and production
scheduling software for manufacturing requirements have not
been critically examined, hence this survey. This survey aimed
at meeting production planning and production scheduling
needs for a connected factory using complete order allocation,
optimizing supply network costs, matching plant demand
capacity, deploying real time buffers, proper sequencing of
assembly lines, scheduling molding lines, optimization of
workforce scheduling and the ability to promise.
Industries such as logistics industry, shipping industry, food
and beverage industry, consumer electronics industry,
automotive industry, discrete manufacturing industry, process
industries and service application industry were visited.
Opinion from these industries geared towards the need for the
use of key enablers to meet advanced manufacturing
scheduling needs such as: production planning, production
scheduling, production sequencing, real-time optimization and
implementation services. A comparative analysis of advanced
planning and scheduling software for manufacturing
requirements with the view to implementing and adopting the
software for a connected factory, is apt. Industry-advanced
digitization practices for industry 4.0 will help to keep pace
with lean inventions.
Research Gap:
Current manufacturing procedures, practice re-configuration
manufacturing system and flexible manufacturing system in
the absence of industry 4.0 implementation. The Industry of
today have not fully adopted and implemented the practice of
Industry 4.0, hence this study.
1.b Production sequencing
Single and multi-line sequencing in industries have been a
bottleneck in some industries in Nigeria hence using patented
algorithm from advanced production planning, production
sequencing and production scheduling software for
manufacturing requirements to utilize modern optimization
techniques will help to solve complex sequencing problems in
industries today. Integrated batching and virtual flow lines
when used can also solve sequencing problems. Strategic
solutions to production scheduling will help to reduce order to
delivery time and maximize through put.
2. MATERIALS AND METHODS
An industrial survey was conducted with ten (10) factories in
Nigeria to ascertain the opinion of industries on
implementation and adoption of advanced production
planning, production scheduling and production sequencing
software for manufacturing requirements. Relevant
information were obtained on the views of the industries on
the research focused on factories and opinions of factory
owners on usage of the advanced manufacturing software,
whether they are ready for implementation and possible
adoption of these solution provided by the software for a
connected factory. From the survey, one of the solutions
provided by the software was selected. Using the concurrent
triangulation design and cronbach alpha to measure the
consistency of responses internally from respondents in the ten
(10) factories that were in line with the true values of the
survey questions, a choice of 450 respondents was used for the
study. The quantitative Data collected was analyzed using
survey questionnaires with questions that were closed-ended.
Heads of industries and factories were administered these
questionnaires via emails and use of Google forms.
Descriptive statistics was used to analyze phase 1 of the
design while the phase 2 which was the qualitative data used
thematic analysis using the cronbach alpha to test for internal
consistency of the answers to the questions.
400 questionnaires sent via email as Google forms were
returned and found useable, and 50 questionnaires distributed
randomly one-on-one for in-depth interview. A total of 450
questionnaires were analyzed. The SPSS 24 was used and a
merger of the phase 1: Quantitative phase and phase 2:
Qualitative phase was integrated and recorded. Figure 3 shows
the concurrent triangulation design.
 planning &
scheduling
software.
1. Full 05 1.25%
Final
result implementation
Phase 1 + of Industry 4.0
Phase 2 will help to
Phase 2: achieve lean
Qualitative phase inventions
Thematic analysis 2. The catalyst for 06 1.50%
in-depth interview
digitization
strategy is
Phase 1: Quantitative quick
Phase scheduling and
Survey questionnaires re-scheduling.
Data analyzed with 3. Throughput in 10 2.50%
descriptive connected
Statistics/Inferential factories is
Concurrent Triangulation Design achieved with
implementation
of industry 4.0
4. There will be 15 3.75%
drastic
Figure 3: Concurrent Triangulation Design (source of reduction in
order to
diagram Author, 2020) delivery time
with full
Research Questions: Using the key enablers, implementation
1. Will optimizing workforce scheduling help to make of industry 4.0
factories connected factories? and full
2. Will adopting industry 4.0 help to actualize the operations of a
practice of scheduling molding lines and properly connected
sequencing assembly lines for connected factory? factory.
3. Will matching planned demand capacity with 5. Using a fully 20 5.00%
deploying real time buffers help to achieve the integrated
adoption of industry 4.0 and make our factories connected
connected? factory and
4. Will optimizing supply network costs and adopting
implementation of a complete order allocation help to industry 4.0
meet planning and scheduling needs for adoption of requires
industry 4.0 for connected factories? vertical and
horizontal data
integration for
a seamless of
3. RESULTS AND DISCUSSIONS flow of data in
Analyzed data produced from distributed closed ended (i)
manufacturing
questionnaires and one-on-one interviews conducted were procurement
used in the design. Quantitative data from the questionnaires and (ii) supply
chain (iii)
(phase 1) and qualitative data from the in-depth interview logistics and
(phase 2) were recorded and merged as presented in the Tables product life
cycle
1a,1b,,2 ,3,4 and 5. management
Table 1a: Results from industry survey questionnaires 6. Adopting 22 5.50%
industry 4.0
Quantitative: Phase 1. requires close
monitoring and
collaboration,
S/N Comparative Respondents (%) information
analysis of the Percentage technology
key enablers expertise and
of the strong
Advanced
 leadership in 13. The use of 20 5.00%
management. Advance
scheduling
software will
7. Industry 4.0 11 2.75%
help to pinpoint
will remove
what, where,
bottlenecks,
why and when
monitor
production
progress in
begins,
connected
considering
factories, quick
constraints.
distribution
14. The solution of 80 20%
8. A connected 14 3.50%
manufacturing
factory that
is optimized
fully adopts
planning,
Industry 4.0
optimized
will operate on
scheduling, and
(i) the lowest
optimized
possible cost
sequencing
and (ii) the
using
highest
manufacturing
possible
soft wares.
quality.
15. There should 05 1.25%
9. Optimizing 10 2.50%
be a unique
workforce
problem
schedule and
definition and
dispatch
configuration
matters will
for a connected
help to solve
factory
detailed
16. There should 32 8%
machine level
be a proper
scheduling and
allocation to
dispatch issues.
planning
10. A fundamental 10 2.50%
bins/slotting in
way to
every
implement
connected
industry 4.0
factory.
and move from
17. Are our 32 8%
industry 3.0 is
industries
to keep pace
ready for
with industry-
industry 4.0.
leading
Implementation
digitization
and
practices
adoption?Yes
11. Integrated 10 2.50%
18. Will adopting 30 7.50%
batching and
and
virtual flow
implementing
lines in our
advanced
factories will
manufacturing
help to
software key
implement
enablers work,
industries 4.0
for industry
12. Using patented 15 3.75%
4.0.? Yes.
algorithms for
19. Industry 4.0 is 10 2.50%
the utilization
all about
of modern
automation,
techniques of
exchanging
optimization in
data and
order to solve
implementing
complex
latest
problems of
manufacturing
sequencing will
technologies
help to adopt
as well as
industry 4.0.
 adopting cyber responses at 36.75% showing that respondents strongly agreed
physical
that: there should be a proper allocation to planning
systems (CPS)
and product bins/slotting in every connected factory (Question 16), our
service systems
industries are ready for industry 4.0 implementation and
(PSS). Do you
agree?Yes. adoption (Question 17), Adopting and implementing advanced
20. Comparatively 43 10.75% manufacturing software key enablers will work for industry
analyzing the
advanced 4.0 (Question 18), Industry 4.0 is allot automation, exchange
planning and data and implementing latest manufacturing technologies as
scheduling
manufacturing well as adopting cyber physical systems (CPS) and product
software the service system (PSS) (Question 19) and also respondents for
implementation
and adoption of Question 20, strongly agreed that comparatively analyzing the
the industry advanced planning and scheduling manufacturing software
software in
connected will help to implement and hasten the adoption of industry
factories is software in connected factories, of which Nigerian factories
possible and
Factories are are fully ready for.
ready for
it.Yes. From Table 2: A record of results from industry survey
TOTAL 400 100% questions for one-on-one indepth interview showed that from
50 respondents, 24 respondents with 48% response, were of
From Table 1a, the/data for comparative analysis of the key the opinion that, matching planned demand capacities with
enablers of the Advanced planning and scheduling software deploying the real time buffers will help to achieve the
was recorded. The respondents with the highest responses adoption of industry 4.0 using the key enablers and making
were respondents that strongly agreed that the solution of our factories connected.
manufacturing is optimized planning, optimized scheduling From the merged results of Table 1 and Table 2 which formed
and optimized sequencing, using manufacturing softwares Table 3, A total of 450 respondents participated in the industry
with 20%. Next to the highest response were the respondents survey questionnaires distributed, answered, retrieved,
who strongly agreed that factories are ready for the analyzed and recorded. A total of 154 respondents at 34.22%
implementation and adoption of industry software for who were captains of industries who already had
connected factories using the advanced planning and implementation plan with prepared guidelines to achieve the
scheduling manufacturing software after careful comparative adoption of industry 4.0 in our manufacturing sector using
analysis with 10.75% response. 80% of the respondents manufacturing for a connected factory and industry roll out,
strongly agreed that our industries are ready for the strongly agreed that adoption of industry 4.0 will make our
implementation and adoption of industry. 4.0. factories connected, 152 respondents (captains of industries)
Table 1b.categorizing the survey questions of the 400 with 33.78% were of the opinion that using manufacturing
responses.
scheduling software to collect data, turn the data collected into
Categories Questions 400 respondents actionable output that feeds the connected supply chain deliver
1 A 1-5 56 14.00%
goods and services on time to improve throughput for a
2. B 6-10 67 16.75%
3. C 11-15 130 32.5% stabilized supply chain, will help to the match planned
4. D 16-20 147 36.75% demand capacity with deploying real time buffers for the
Total 400 100%
implementation of the industry 4.0 and in turn, make our
From Table 1b, the survey questions of 400 respondents were factories connected. 78 respondents at 17.33% were of the
categorized into A – D categories. Category D comprising of view that adopting industry 4.0 will help to actualize practice
questions 16-20 recorded the highest response with 147 of scheduling molding lines for a connected factory. Only 66
respondents at 14.67% were of the view that factories will complete order allocation (using production scheduling
become connected if workforce schedule is optimized. software) recorded 0.99147, Matching planned demand
VALIDATION OF RESULTS capacity with deploying real time to adopt industry 4.0 (using
Reliability test using the cronbach alpha was carried out to production planning software) recorded 0.97910, while
check for internal consistency of the comparative analysis of Optimizing workforce with production sequencing recorded
the key enablers of the manufacturing software for 0.97095. The cronbach alpha obtained for Adoption of
implementation and adoption in connected factories. Using the industry 4.0 showed reasonable consistency as compared with
rule of thumb 0≥0.5 is poor and 0≥ 0.4 is unacceptable, and 0≥0.9 is excellent in the scale as recorded by [17]. The
0≥0.9 is excellent, the values obtained and analyzed showed cronbach values were accepted as they tally with reliability
that adopting industry 4.0 with values between 0≥0.9 is analysis of [17].
excellent. CONCLUSION
Table 4: Results from reliability test using the cronbach 1. The efficiency of the concurrent triangulation design has
alpha been proven to be an efficient method to compare,
MS MS MS MS analyze and determine the ideal key enabler to be
Colu 14121.6 5645.5 9169.5 6258.4 adopted and implemented for the industry 4.0
mn
Error 120.322 66.95 191.5556 181.767 connected factories. Adoption and implementation of
1 – 1- 1- 1- Industry 4.0 using production sequencing, real time
Alph [120.322/14 [66.95/56 [191.5556/9 [181.767/6
a 121.6] 45.5] 169.5] 258.4] optimization, production planning and production
value 0.991479 0.98814 0.97910 0.97095 scheduling soft wares, has proven to be the most
s/N 4 2 3 1 appropriate for industry 4.0 connected factories.
2. Using the cronbach alpha (α) analysis, with 0≥0.9 is
Table 5: Results from reliability test of the cronbach alpha excellent; all the results were excellent with 0.99147,
with items 0.98814, 0.97910 and 0.97095. An optimized value
S/N. Comparative analysis of the (X) No. of of 0.982415 was obtained. The highest value α =
key enablers of the Cronbach Items
advanced software Alpha 0.99147 show that : optimizing supply network cost
(planning, scheduling and implementing a complete order allocation using a
sequencing and
optimization) for connected production scheduling sequence was chosen over
factories. other key enablers.
1 Optimizing workforce with 0.97095 56
production sequencing. 3. From the total of 450 respondents to the entire questions,
2. Practice of scheduling 0.98814 67 using the production planning software to keep pace with
molding line for a connected
factory using real time industry-leading digitization practices, adoption of industry
optimization. 4.0 in industries had the highest number of responses with 154
3. Matching planned demand 0.97910 130
capacity with deploying real responses at 34.22%, 152 responses for implementation of
time to adopt industry 4.0 industry 4.0 in industries with 33.78%, 78 responses at
(using production planning
software) 17.33% using real time optimization software agreed that
4. Optimizing supply network 0.99147 147 scheduling molding lines was acceptable and 66 respondents
cost and implementing a
complete order allocation at 14.67% for production sequencing software agreed that
(using production optimizing work force schedule will produce connected
scheduling software)
factories.

From Table 4 and 5, The Practice of scheduling molding line It can therefore be concluded after a comparative analysis of

for a connected factory using real time optimization recorded the key enablers of the advanced manufacturing scheduling

0.98814, Optimizing supply network cost and implementing a software which are production planning software, production
scheduling software, production sequencing software, real
time optimization software, that: adopting and implementing the survey. God bless Igbinedion University for sponsoring
the industry 4.0 for a connected factory using advanced this research.
planning and scheduling software, will help improve
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the captains of the ten industries that willingly participated in

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