Investigating smart manufacturing process implementation in the Indian manufacturing industries using tecnomatix and response surface methodology

Digital manufacturing is revolutionizing industry by enhancing efficiency, sustainability, and competitiveness. Nonetheless, existing research highlights the necessity for standardized protocols to enhance interoperability among digital manufacturing technologies. This study, using data from a Sanand, Gujarat, India based manufacturing plant, connects digital manufacturing with advanced computational models to optimize productivity, quality, time, and resource utilization. It identifies key parameters, including machine availability, production hours, conveyor speed, trolley count, Parts Produced (PP), Surface Finish (SF), Down Time (DT), and Scrap Rate (SR), and investigates layout changes to improve PP, SF, DT, and SR. Tecnomatix Plant Simulation and Delmia V5 software analyze four production line designs, with PLS 4, utilizing both conveyors and trolleys, emerging as the most effective. By optimizing factors and parameters, substantial improvements are achieved, with a 126%, 143%, 42%, and 36% enhancement in PP, SF, DT, and SR, respectively. The study’s reliability is confirmed by the Response Surface Methodology.