Developing Frameworks for Reducing Waste and Improving Resource Efficiency in Manufacturing using Industry 4.0

Developing Frameworks for Reducing Waste and Improving Resource Efficiency in Manufacturing using Industry 4.0

Mr. Harshvardhan Nikam 1, a , Mr. Avinash Somatkar2, b aVishwakarma Institute of Technology Pune,harshvardhan.22020239@viit.ac.in

b Vishwakarma Institute of Information Technology Pune, avinash.somatkar@viit.ac.in,

I. Abstract

The implementation of Industry 4.0 technologies in the manufacturing sector has opened up new pathways for sustainability by improving resource efficiency and minimizing waste. The emergence of cyber-physical systems, the Internet of Things (IoT), artificial intelligence, big data analytics, and digital twins supports the development of intelligent and sustainable manufacturing practices. This research synthesizes key insights from existing literature to propose a comprehensive framework aimed at waste reduction and resource efficiency in manufacturing through the application of Industry

4.0. The literature suggests that digital transformation is instrumental in facilitating lean manufacturing, circular economy practices, and sustainable waste management. Hybrid multi-criteria decision-making methodologies, smart factory frameworks, and machine learning-based predictive models have demonstrated enhancements in productivity, reductions in waste, and improvements in environmental sustainability. Case studies spanning various industries, from micro, small, and medium enterprises (MSMEs) to large-scale manufacturing, highlight the role of Industry 4.0 in optimizing supply chains, conserving energy, and enhancing overall equipment effectiveness (OEE). Despite these advancements, challenges such as high implementation costs, lack of standardization, and environmental concerns regarding Industry 4.0 technologies persist. Addressing these challenges necessitates a structured roadmap that incorporates lean methodologies, circular economy principles, and sustainable innovation. The findings of this study provide practical recommendations for policymakers, industry professionals, and researchers to harness the potential of Industry 4.0 for sustainable manufacturing. Through the utilization of smart automation, data-driven decision-making, and collaborative digital ecosystems, the manufacturing sector can significantly contribute to achieving Sustainable Development Goals (SDGs) while maintaining competitiveness in the global market. Future research should focus on overcoming barriers to adoption and refining frameworks for the seamless integration of Industry 4.0 in sustainability-focused

manufacturing.

Keywords: Industry 4.0, sustainable manufacturing, resource efficiency, waste reduction, cyber-physical systems, Internet of Things (IoT), artificial intelligence, big data analytics, digital twins, lean manufacturing, circular economy, smart factory, predictive models, environmental sustainability, multi-criteria decision-making (MCDM), overall equipment effectiveness (OEE), Sustainable Development Goals (SDGs), data-driven decision making, manufacturing innovation, digital transformation