**1. Introduction**

Previous industrial revolutions have given birth to various breakthroughs in the rail industry ranging from the development of trains powered by diesel to electric. In recent times, the advent of the fourth industrial revolution (4IR) and robust digital solutions have produced advance technology for manufacturing. As shown in **Figure 1**, this innovative advances in manufacturing relates to automation and robotics [1, 2], Additive Manufacturing (AM) including subsets like 3D printing, Rapid Prototyping, Direct Digital Manufacturing [3, 4], Cyber-physical systems (CPS) [5], Physical Internet (PI) and Internet of Things (IoT) in the logistics and transportation area [6, 7] as well as artificial intelligence (AI), augmented reality,

#### **Figure 1.**

*Elements of the fourth industrial revolution relating to manufacturing.*

big data analytics and digital solutions in the informatics field [8, 9]. Many industries are now embracing the fourth industrial revolution known as Industry 4.0 amidst dynamic production challenges and increasing market forces. For instance, artificial intelligence (AI) find applications in process planning and optimization, robotic development, decision making, system control as well as pattern recognition involving automatic incident detection, image processing for traffic data collection and for identifying cracks in rail structures [10, 11]. In the same vein, artificial intelligence can also be explored in rail car manufacturing for nonlinear prediction relating to traffic demand, the deterioration of rail infrastructure as a function of traffic, construction, and environmental factors. In addition, the quest for smart, high volume and intelligence systems is a major driver that propels manufacturers' into the development of new production technologies, which incorporates the concept of the FIR.

The aim of these technological advances in the manufacturing sector is to increase productivity, promote automation and control and enhance good product quality and conformity to standards. This will increase equipment reliability and availability thereby making the supply chain, assembly and production lines smarter. These have also brought about a tremendous growth and innovation potential for global value chain setups. These manufacturing technologies are enhancing high rates of production at an effective unit cost. One of the advantages of high volume production is that costs are expected to reduce as the volume of production increases.

This work focuses on the application of the Fourth Industrial Revolution (4IR) characterised by emerging robotic solutions with smart monitoring system and the exploration of additive manufacturing for rapid prototyping during assembly operations in the rail car industry. The use of monitoring systems will help in diagnosing and tracking the technical conditions during the assembly operation of the rail car using the online mode (in real time) in order to obtain the system

**155**

are listed as follows:

carbon fibre etc.

*Application of the Fourth Industrial Revolution for High Volume Production in the Rail Car…*

and measurement performance [12–14]. The rail car manufacturers are increasingly testing the potential of additive manufacturing (AM) to break creative barriers within the three major trends driving the industry namely; product innovation, high-volume direct manufacturing and fuel efficiency with increased performance [15, 16]. The complexity and intersecting technologies driving the fourth industrial revolution and the breadth of their impact necessitates the development of innovative approaches to implement and diffuse the current and emerging technologies for rail car development. The concept of mass production involves the development of tools and automated equipment for the production of interchangeable parts and products in order to strike the right balance among cost,

The merit of mass production systems include the development of large products to a high degree of surface finish and precision, significant reduction in the cost of labour due to the automated nature of the assembly line and resultant reduction in the overall production cost. The effective production control and monitoring can increase process improvement with good information flow with data acquisition and management systems. This fast rate of production will enable prompt scheduling, realistic forecast and product distribution with overall increase in profitability. Although, the initial set up of mass production lines is energy and cost intensive but the initial cost are often offset as the business breaks even over time due to profit from high volume production. The major drawbacks of the mass production systems include; the replacement of personnel with automated systems and the fact that the system is relatively inflexible to production changes, which are integral part

The fourth industrial revolution provides solutions for many complex problems in the rail industry. If adequately deployed, it has the potential to revolutionise the assembly and operation of rail car systems, leading to transformation in the development, operation and maintenance. This will deliver benefits to the rail industry and users as well as the wider economy, including innovative approach, increased capacity, improved performance and enhanced safety for passengers and workers. This means that while the rail industry will be able to save cost considerably at increased efficiency and delivery, the operational activities and maintenance will be more reliable and effective. The developed framework for rail car development with

The part manufacturer uses innovative material based solutions for parts development while the component manufacturers develops the parts into components which is supplied to the sub assembly manufacturer. The sub assembly manufacturer integrates different components into a sub assembly unit and develops a feasible framework for prototyping. The original equipment manufacturer (OEM) does the final assembly of various sub-systems into a system while the Information Communication technology unit (ICT) and logistics facilitates the supply chain relationships in order to keep the stakeholders abreast of advances in technology, demand and supply as well as planning and production. Some of the materials employed for the rail car manufacturing as well as the component parts developed into subassembly and final assembly

a.Materials: Aluminium, fabrics, stainless steel, steel, rubber, plastic, glass,

the inclusion of supply chain activities is presented in **Figure 2**.

*DOI: http://dx.doi.org/10.5772/intechopen.88703*

quality and quantity.

of the production processes.

**2. The developmental framework**

#### *Application of the Fourth Industrial Revolution for High Volume Production in the Rail Car… DOI: http://dx.doi.org/10.5772/intechopen.88703*

and measurement performance [12–14]. The rail car manufacturers are increasingly testing the potential of additive manufacturing (AM) to break creative barriers within the three major trends driving the industry namely; product innovation, high-volume direct manufacturing and fuel efficiency with increased performance [15, 16]. The complexity and intersecting technologies driving the fourth industrial revolution and the breadth of their impact necessitates the development of innovative approaches to implement and diffuse the current and emerging technologies for rail car development. The concept of mass production involves the development of tools and automated equipment for the production of interchangeable parts and products in order to strike the right balance among cost, quality and quantity.

The merit of mass production systems include the development of large products to a high degree of surface finish and precision, significant reduction in the cost of labour due to the automated nature of the assembly line and resultant reduction in the overall production cost. The effective production control and monitoring can increase process improvement with good information flow with data acquisition and management systems. This fast rate of production will enable prompt scheduling, realistic forecast and product distribution with overall increase in profitability. Although, the initial set up of mass production lines is energy and cost intensive but the initial cost are often offset as the business breaks even over time due to profit from high volume production. The major drawbacks of the mass production systems include; the replacement of personnel with automated systems and the fact that the system is relatively inflexible to production changes, which are integral part of the production processes.

## **2. The developmental framework**

The fourth industrial revolution provides solutions for many complex problems in the rail industry. If adequately deployed, it has the potential to revolutionise the assembly and operation of rail car systems, leading to transformation in the development, operation and maintenance. This will deliver benefits to the rail industry and users as well as the wider economy, including innovative approach, increased capacity, improved performance and enhanced safety for passengers and workers. This means that while the rail industry will be able to save cost considerably at increased efficiency and delivery, the operational activities and maintenance will be more reliable and effective. The developed framework for rail car development with the inclusion of supply chain activities is presented in **Figure 2**.

The part manufacturer uses innovative material based solutions for parts development while the component manufacturers develops the parts into components which is supplied to the sub assembly manufacturer. The sub assembly manufacturer integrates different components into a sub assembly unit and develops a feasible framework for prototyping. The original equipment manufacturer (OEM) does the final assembly of various sub-systems into a system while the Information Communication technology unit (ICT) and logistics facilitates the supply chain relationships in order to keep the stakeholders abreast of advances in technology, demand and supply as well as planning and production. Some of the materials employed for the rail car manufacturing as well as the component parts developed into subassembly and final assembly are listed as follows:

a.Materials: Aluminium, fabrics, stainless steel, steel, rubber, plastic, glass, carbon fibre etc.

*Mass Production Processes*

big data analytics and digital solutions in the informatics field [8, 9]. Many industries are now embracing the fourth industrial revolution known as Industry 4.0 amidst dynamic production challenges and increasing market forces. For instance, artificial intelligence (AI) find applications in process planning and optimization, robotic development, decision making, system control as well as pattern recognition involving automatic incident detection, image processing for traffic data collection and for identifying cracks in rail structures [10, 11]. In the same vein, artificial intelligence can also be explored in rail car manufacturing for nonlinear prediction relating to traffic demand, the deterioration of rail infrastructure as a function of traffic, construction, and environmental factors. In addition, the quest for smart, high volume and intelligence systems is a major driver that propels manufacturers' into the development of new production technologies, which incorporates the

*Elements of the fourth industrial revolution relating to manufacturing.*

The aim of these technological advances in the manufacturing sector is to increase productivity, promote automation and control and enhance good product quality and conformity to standards. This will increase equipment reliability and availability thereby making the supply chain, assembly and production lines smarter. These have also brought about a tremendous growth and innovation potential for global value chain setups. These manufacturing technologies are enhancing high rates of production at an effective unit cost. One of the advantages of high volume production is that costs are expected to reduce as the volume of

This work focuses on the application of the Fourth Industrial Revolution (4IR) characterised by emerging robotic solutions with smart monitoring system and the exploration of additive manufacturing for rapid prototyping during assembly operations in the rail car industry. The use of monitoring systems will help in diagnosing and tracking the technical conditions during the assembly operation of the rail car using the online mode (in real time) in order to obtain the system

**154**

concept of the FIR.

**Figure 1.**

production increases.


In order to maximise the benefits of the advanced manufacturing technologies, the perceived industrial key players can develop the theory driving the elements of the new industrial revolution into practical knowledge as stated in the following subsections.
