Smart Manufacturing

Explore the dramatic changes brought on by the new manufacturing technologies of Industry 4.0

In Smart Manufacturing, The Lean Six Sigma Way, Dr. Anthony Tarantino delivers an insightful and eye-opening exploration of the ways the Fourth Industrial Revolution is dramatically changing the way we manufacture products across the world and especially how it will revitalize manufacturing in North America and Europe.

The author examines the role and impact of a variety of new Smart technologies including industrial IoT, computer vision, mobile/edge computing, 3D printing, robots, big data analytics, and the cloud. He demonstrates how to apply these new technologies to over 20 continuous improvement/Lean Six Sigma tools, greatly enhancing their effectiveness and ease of use.

The book also discusses the role Smart technologies will play in improving:

• Career opportunities for women in manufacturing
• Cyber security, supply chain risk, and logistics resiliency
• Workplace health, safety, and security
• Life on the manufacturing floor
• Operational efficiencies and customer satisfaction

Perfect for anyone involved in the manufacturing or distribution of products in the 21st century, Smart Manufacturing, The Lean Six Sigma Way belongs in the libraries of anyone interested in the intersection of technology, commerce, and physical manufacturing.

Foreword

Preface

Acknowledgments

About the Author

About the Contributors

Chapter 1. Introduction to Industry 4.0 and Smart Manufacturing
Anthony Tarantino, Ph

Chapter 2. Lean Six Sigma in the Age of Smart Manufacturing
Anthony Tarantino, PhD

Chapter 3. Continuous Improvement Tools for Smart Manufacturing
Anthony Tarantino, PhD

Chapter 4. Improving Supply Chain Resiliency Using Smart Technologies
Anthony Tarantino, PhD

Chapter 5. Improving Cybersecurity Using Smart Technology
Craig Martin

Chapter 6. Improving Logistics Using Smart Technology
Frank Poon

Chapter 7. Big Data for Small, Midsize, and Large Organizations
Omar Abdon and Randy Shi

Chapter 8. Industrial Internet of Things (IIoT) Sensors
Deb Walkup and Jeff Little

Chapter 9. Artificial Intelligence, Machine Learning, and Computer Vision
Steven Herman

Chapter 10. Networking for Mobile Edge Computing
Jeff Little

Chapter 11. Edge Computing
Vatsal Shah and Allison Yrungaray

Chapter 12. 3D Printing and Additive Manufacturing
Bahareh Tabatabaei, Rui Huang, and Jae-Won Choi

Chapter 13. Robotics
Thomas Paral, PhD

Chapter 14. Improving Life on the Factory Floor with Smart Technology
Miles Schofield and Aaron Pompey, PhD

Chapter 15. Growing the Roles for Women in Smart Manufacturing
Maria Villamil and Deborah Walkup

Case Studies

Case Study 1. Automating Visual Inspection Using Computer Vision
Anthony Tarantino, PhD

Case Study 2. Barcoding, the Most Ubiquitous and Most Critical IIoT Technology
Anthony Tarantino, PhD

Case Study 3. Improving Safety with Computer Vision
Anthony Tarantino, PhD

Case Study 4. COVID-19 Accelerates the Adoption of 3D Printing
Anthony Tarantino, PhD

Case Study 5. How Mobile Apps Benefit Small to Midsize Enterprises
Anthony Tarantino, PhD

Case Study 6. Using Factory-Floor Touch Screens to Improve Operations
Miles Schofield and Aaron Pompey

Case Study 7. Edge Computing to Improve Operations
Allison Yrungaray

Case Study 8. Five Dangerous Jobs Robots Can Do Well
Alex Owen-Hill

Answers to Sample Questions

Links to Continuous Improvement Templates

Index

ANTHONY TARANTINO, PhD, is a Master Black Belt in Lean Six Sigma and has lead over 30 continuous improvement projects for Cisco Systems, IBM, Oracle, and KPMG Consulting spanning a twenty-year period. He has been an adjunct faculty member at Santa Clara University for over a decade. For the first 25 years of his career he worked in the manufacturing industry as a supply chain manager earning certifications in purchasing from ISM and in production and inventory management from APICS. This is his fifth book for Wiley and Sons.

2020 and 2021 confronted manufacturers with a variety of unprecedented operational challenges. As they now seek to reopen and restart production, many are realizing an opportunity to reimagine work and operations so they can emerge from the economic downturn caused largely by COVID-19 with greater agility, resilience, and ingenuity.

Smart Manufacturing: The Lean Six Sigma Way delivers an incisive and thought-provoking discussion of the various ways the Fourth Industrial Revolution is changing the way we manufacture products across the world and how it can revitalize manufacturing in North America and Europe.

In the book, accomplished smart manufacturing expert and consultant Dr. Anthony Tarantino offers readers a proven and easy-to-follow framework for manufacturing transformation to use in continuous improvement, Lean, and Six Sigma initiatives and other ongoing programs. It presents simple, low-cost tools to kickstart any smart manufacturing program, providing a foundational understanding of key Industry 4.0 technologies and methodologies that can work in any organization.

The author includes interviews with and contributions from celebrated manufacturing professionals who shed light on some of the most pressing issues in the sector. Going beyond mere truisms about “digital transformation” and “design thinking,” Smart Manufacturing: The Lean Six Sigma Way presents practical solutions to real-world problems by showing readers how to improve product quality, eliminate waste, reduce production time, and lower costs.

Perfect for executives, managers, controllers, and operations professionals in manufacturing firms, Smart Manufacturing: The Lean Six Sigma Way will also earn a place in the libraries of information technology managers and manufacturing innovators seeking an eye-opening treatment of the latest impactful technologies in a wide range of industries.

“It is a rare book that fully and effectively combines production management concepts and practices. This book can be very effective in helping to realize smart manufacturing in the factory to lower cost, improve customer satisfaction, and improve employee morale.”
—Jianfeng Du, Founder and CEO, MPMC Powertech Corp., China’s Leading Hybrid Energy and Battery Storage Solution Innovator

“The author covers all of the building blocks that will be at the core of the smart technologies wave that unfolds in the next few years. The book is a great reference to have and I strongly encourage you to read it!”
—Najib Khouri-Haddad, General Partner, Sway Ventures

“Dr. Tarantino’s newest tome, Smart Manufacturing: The Lean Six Sigma Way, is a tour de force and comprehensive work that will appeal to both readers who are new to the field as well as accomplished experts. In addition to providing fresh perspectives on the latest smart manufacturing approaches, he and his chapter co-authors also expand on several of the most pressing challenges and important issues facing the United States and the global manufacturing economy, including supply chain resiliency, cybersecurity, big data, as well as the rapid adoption of game-changing technologies including artificial intelligence, machine learning, and edge computing. This encompassing volume is highly recommended reading for anyone interested in understanding the state-of-the-art in the rapidly evolving advanced and smart manufacturing landscape.
—Daniel Kirk, Ph.D., Interim Dean of Engineering, Florida Institute of Technology

“Smart Manufacturing: The Lean Six Sigma Way is a comprehensive and accessible overview of the technologies that are transforming industry. Relevant to both students and practitioners, the book places smart manufacturing in its historical context while clearly bringing across the powerful disruptive potential of Industry 4.0. Anthony Tarantino’s book provides insight into this emerging paradigm that will be of huge benefit to the reader.”
—Harry Malins, Chief Innovation Officer, UK’s Aerospace Technology Institute

“Industry 4.0 is underway. Data analytics, augmented reality, artificial intelligence, collaborative robots, additive manufacturing, and other technologies are already helping manufacturers increase efficiency, reduce downtime, lower prices, and improve service, delivery, and quality. Industry 4.0 will inevitably lead to new types of work and new ways of working. It will require changes to company structures and relationships between companies. Businesses must understand what they want to achieve and then develop an implementation strategy. This book will help you get there.
—John Sprovieri, chief editor, ASSEMBLY magazine

“A wonderful book to introduce undergraduate students to a career in operations or manufacturing, a long-overlooked field. The book is easy to read and will allow students to understand the challenges facing those implementing industry 4.0. Particularly enlightening in describing how smart manufacturing will open up opportunities for women who choose a STEM field for a career.”
—Deborah Cernauskas, Ph.D., Professor of Business Analytics and Finance, Chair Undergraduate Business (ret), Benedictine University