Lean Manufacturing 4.0-dynamic physical and cybernetic system for Industry 4.0

The intelligent manufacturing system is realized through fusion between the production system with information and communication technologies. This allows to build a digital twin of physical production system, the two being connected and communicate each other data in real time about production status and progress. The existing Industry 4.0 physical system identify the active production resources, who are directly involved in the production processes, and of the passive ones, who have supporting roles. In Industry 4.0 those resources are directly interconnected with the corresponding cyber elements in order to supervise the whole system and the corresponding processes. Into this architecture, the physical production passive and active resources will form a dynamic subsystem, through which one can manage the physical and cybernetic changeable manufacturing processes and various products, in different manufacturing stages. This paper presents a solution to change the cyber-physical system by replacing the production physical active elements with those elements who need to change on the production line and the corresponding digital resources, including the specific Lean 4.0 production system tools who supervises the manufacturing cell and controls the execution. This dynamic system allows achieving a higher level of the production system.