Advancing towards industry 4.0: A maturity model for smart shop floor control

Abstract

This research introduces the smart Shop Floor Control Maturity Model (S²FC MM), a comprehensive framework designed to assess the maturity of shop floor control function in the context of Industry 4.0 environments. Developed through a meticulous Design Science Research approach, the model combines mixed methods such as literature surveys, expert interviews, focus groups, an observational case study, and fuzzy expert system modeling. S²FC MM is designed from a socio-technical systems theory (STS) lens. Additionally, it was applied to measure the maturity of a multinational steel manufacturing company dealing with an Industry 4.0 project in the past three years. S²FC MM is distinguished by its granular, multi-layer structure, comprising five maturity focus areas, twenty implementation key factors, ninety-six smart capabilities, and five progressive maturity levels. A key feature of the model is its fuzzy rule-based self-assessment tool, which accurately reflects managerial perceptions of maturity levels, addressing the imprecision often found in such evaluations. Applying our S²FC MM in a large steel manufacturing company has showcased its effectiveness. It has significantly aided shop floor managers and steel company professionals in identifying key operational improvements and systematically navigating the progression of maturity levels within their operations. Consequently, the S²FC MM emerges as a valuable tool for facilitating the transition of the shop floor control function towards smart, technology-driven operations, providing a clear pathway for manufacturing companies to maximize value-creation and enhance performance in the Industry 4.0 era. Theoretically, our research extends the socio-technical systems theory to smart shop floor control by integrating technological and social dimensions essential for Industry 4.0. The proposed S²FC MM framework defines five focus areas that balance human and technical elements. By tailoring socio-technical systems theory principles to manufacturing-specific challenges, the study provides a socio-technical perspective for managing digital transformation in production environments.