The potential of industry 4.0 Cyber Physical System to improve quality assurance: An automotive case study for wash monitoring of returnable transit items

Abstract The aim of the research outlined in this paper is to demonstrate the implementation of a Cyber-Physical System (CPS) within the Automotive Industry for the monitoring and control of Returnable Transit Items (RTIs) toward improved quality assurance and process compliance. The socio-technical issues encountered during the real-world implementation are discussed to inform future design Automotive RTI’s are utilised in the transportation of both components and subsequently assembled products at the beginning and end of life stages. The implemented system utilises passive Ultra-High Frequency (UHF) Radio Frequency IDentification (RFID) tags for the identification of metal RTIs via associated plastic separators, whilst a distributed network of RFID portals was integrated within the RTI working environment to capture and characterise their movements. The requirements, design process and resulting architecture are presented alongside the results and lessons learnt from an implementation within the automotive industry. Through the integration of business processes, analytics and tacit domain knowledge, a real-time model of the state of RTIs was developed to support decision making by a range of stakeholders. This research contributes to the knowledge of CPSs requirements identification, design, deployment and the challenges faced within real world asset monitoring and traceability within the automotive industry. Areas for future research to support the next generation of RTI traceability, monitoring and control systems are presented.