**2.1 Dedicated production lines**

Producing large quantities of standardized products known as mass production is the American system of production. This production strategy began with the launch of the Henry Ford Moving Assembly Line, which culminated in a high product demand following World War II. In this production era, dedicated production lines represented a key paradigm in production industries. Dedicated production lines produced large quantities for a single part type and very profitable when demand for this part is high [12]. **Figure 3** shows an example of dedicated production lines for the manufacture of cars. The dedicated production lines are costeffective as long as they can operate at full capacity. However, market pressure from global competition and over-capacity worldwide is increasing. In order to maintain the varieties of products, many dedicated production lines are required [13]. This increases the overall factory cost significantly.

#### **Figure 2.**

*The revolution of production systems.*

#### **Figure 3.** *Dedicated production lines for the manufacture of cars.*

Dedicated production lines also have its disadvantages. According to Delorme et al. [14], a dedicated production line requires a large investment and needs to be used for a long time to be competitive. The dedicated line is very complicated to change, and if necessary, it will require a high cost and effort to reconfigure. In addition, breakdowns of the system are also a crucial issue. This is attributed to the interrelatedness of each station in the line where the entire line has to be halted if one of the stations fails. FMS was introduced to overcome these problems.

#### **2.2 Flexible manufacturing systems**

The demand for product variety rose in the late 1980s, which leads to the paradigm of mass customization [15]. Since then, there has been a major increase in the number of product variations offered by product manufacturers. This has been proven by the increment in numbers of different car models in the United States of America from 44 in 1969 to 165 in 2006 [16]; due to many choices of components and accessories combinations offered for each car model. The segmenting

**173**

**Figure 4.**

*Revolution of Production System for the Industry 4.0 DOI: http://dx.doi.org/10.5772/intechopen.90772*

**2.3 Reconfigurable manufacturing system**

system.

on investment.

cyber-physical system.

this trend will continue [22].

*An example of an FMS developed by FESTO group.*

of product markets and international competition both led to the development of highly diversified and customized products that required FMS as their production

The FMS concept allows production companies to predefine a range of production processes within the context of the system capabilities (**Figure 4**). In a single system configuration, FMS enables production companies to quickly and easily activate a range of product models on request, thus improving their competitiveness and profitability through a highly efficient system design [17]. Companies can effectively manufacture a number of product types in the same system. However, when an unexpected production requirement arises, the adaptability of FMS is constrained by limitations and synchronization problems [18]. FMS are not designed for structural changes and therefore cannot respond to abrupt market fluctuations, such as varying user requirements and major equipment failures [19]. Similarly, a study by Koren and Shpitalni [11] showed that there is a growing need for FMS to be reconfigured and reused more efficiently in order to maximize return

The pervasive internet presence, computational and analysis software, and the introduction of modern responsive production systems, such as 3D printing, pose an opportunity for a new product development paradigm: personalizing products according to individual needs and preferences. Through collaboration with production companies and other consumers, customers are able to design and realize their innovative products. This co-development process enables customers to engage in design, product modeling and simulation, fabrication, and assembly processes that respond quickly to the needs and preferences of customers, by means of the open-product architecture [20], the on-demand production systems, and adaptive

The heterogeneity of consumer demands has forced enterprises to offer a higher number of product variants, produced in smaller batch sizes. A huge increase in product varieties in different product ranges and sectors can be noticed [21], and

*Revolution of Production System for the Industry 4.0 DOI: http://dx.doi.org/10.5772/intechopen.90772*

*Mass Production Processes*

**Figure 2.**

**Figure 3.**

*The revolution of production systems.*

**172**

Dedicated production lines also have its disadvantages. According to Delorme et al. [14], a dedicated production line requires a large investment and needs to be used for a long time to be competitive. The dedicated line is very complicated to change, and if necessary, it will require a high cost and effort to reconfigure. In addition, breakdowns of the system are also a crucial issue. This is attributed to the interrelatedness of each station in the line where the entire line has to be halted if

one of the stations fails. FMS was introduced to overcome these problems.

The demand for product variety rose in the late 1980s, which leads to the paradigm of mass customization [15]. Since then, there has been a major increase in the number of product variations offered by product manufacturers. This has been proven by the increment in numbers of different car models in the United States of America from 44 in 1969 to 165 in 2006 [16]; due to many choices of components and accessories combinations offered for each car model. The segmenting

**2.2 Flexible manufacturing systems**

*Dedicated production lines for the manufacture of cars.*

of product markets and international competition both led to the development of highly diversified and customized products that required FMS as their production system.

The FMS concept allows production companies to predefine a range of production processes within the context of the system capabilities (**Figure 4**). In a single system configuration, FMS enables production companies to quickly and easily activate a range of product models on request, thus improving their competitiveness and profitability through a highly efficient system design [17]. Companies can effectively manufacture a number of product types in the same system. However, when an unexpected production requirement arises, the adaptability of FMS is constrained by limitations and synchronization problems [18]. FMS are not designed for structural changes and therefore cannot respond to abrupt market fluctuations, such as varying user requirements and major equipment failures [19]. Similarly, a study by Koren and Shpitalni [11] showed that there is a growing need for FMS to be reconfigured and reused more efficiently in order to maximize return on investment.
