Evaluation of Industry 4.0 Readiness Level Cases From Turkey
Evaluation of Industry 4.0 Readiness Level Cases From Turkey
Evaluation of Industry 4.0 Readiness Level Cases From Turkey
0 Readiness
Level: Cases from Turkey
1
Department of Engineering Management, Bahcesehir University, Istanbul, Turkey
[email protected]
2
Department of Management Engineering, Istanbul Technical University, Istanbul, Turkey
{bolat,gozlus}@itu.edu.tr
Abstract. The Fourth Industrial Revolution or Industry 4.0 is the name of recent
digital transformation era. This transformation is conducted to improve digital
operational abilities, perform collaboration and integration in the ecosystem,
manage data, and develop cyber security. Industry 4.0 has become a very popular
issue recently, but there is lack of understanding about its impact on real practices
and the barriers expected to be encountered in the near future. Under the uncertain
environment of digitalization, the companies need an evaluation method to define
their strengths and weaknesses in the adaptation process. In this study, the meth‐
odologies for evaluating Industry 4.0 readiness level of companies are reviewed,
and one of the most applicable methods is utilized for evaluation of three leading
Turkish companies from different industries. In addition, the awareness of compa‐
nies is also evaluated in terms of operational and socio-economical perspectives.
Little research has been conducted on (1) reviewing the opinions of the companies
on the socio-economic effects of Industry 4.0 and (2) evaluating Industry 4.0
readiness in developing countries. This study contributes by evaluating three
cases dealing with the perceptions, awareness, and readiness of the Turkish
companies in Industry 4.0 adaptation process. The result of the research shows
that companies failing to develop road maps and new workforce planning strat‐
egies in the adaptation process under the uncertain environment of Industry 4.0
prefer to be the follower rather than the pioneer.
1 Introduction
The new age of digital transformation is called the Fourth Industrial Revolution or
Industry 4.0. The purpose of this transformation to structure digital abilities, perform
collaboration in the ecosystem, manage data, to manage cyber security, and implement
two-speed systems/data architecture to differentiate quick-release cycles [1]. It directly
affects design, production, distribution, and exploitation processes [2]. The strategies of
product life cycle have become more global, multidisciplinary, innovation oriented, and
customer focus [3]. Industry 4.0 applications provide many advantages for the
management of new product life cycles by (1) increasing flexibility, (2) decreasing lead
times, (3) increasing customer specific production with small batches, and (4) proposing
new offerings by the help of big data analytics [4].
Popular technologies in Industry 4.0 are simulation, augmented reality, autonomous
robots, Internet of Things (IoT), cloud, cybersecurity, additive manufacturing, horizontal
and vertical system integration, and Big Data analytics [5]. Utilization of computerized,
intelligent, flexible and highly efficient systems, synchronization of material flow, and inte‐
grating customers, suppliers and companies have been increased by the effect of the popular
technologies of Industry 4.0 [6]. The main elements of Industry 4.0 are connection between
machines, equipment, systems and organizations within the value chain and to control the
process autonomously. Such developments will directly change the production processes
and the structure of factories. Factories become smarter, and include autonomous equip‐
ment. It becomes automatic to plan, organize and control production process [6]. Besides
that, utilization of internet technology has been increasing the intelligence of factories,
improving ergonomic oriented issues, and increasing the efficiency of resources [7].
Enhancement of interaction between production machines can be achieved by the help of
IoT and augmented reality techniques. IoT can let machines obtain and analyze the infor‐
mation via computer network. Furthermore, by establishing effective prediction models,
unexpected negative events can be detected earlier [6]. It is remarkable to mention that
technological effect has not only originated from the developments made by the effect of
internet. There are more technological fields [8]:
• Information and communication technology
• Technologies for keeping the security of basic sources (food, water and energy)
• New health technologies
• New manufacturing and automation technologies.
The potential of these technologies can differ according to the industry. For instance,
in logistics industry, Physical Internet (PI), which consists of global logistics web on
physical, digital and operational interconnectivity, is very popular. By utilization of such
kind of IT oriented tools, analysing, communicating, designing, understanding, and
optimizing operations have been improved in logistics. Also, smart containers which
have identifiers and IoT elements are connected to internet [9].
Although Industry 4.0 has become a popular issue recently, most of the managers
are not aware of its effects on real practices. One of the most leading surveys on Industry
4.0 was conducted by the Institute for Industrial Management at the University of
Aachen in Germany by gathering the responses of more than 400 developed countries.
The results indicate that 85% of the production companies realize the importance of the
topic; and the most important developments will be performed within the next five years
in the fields of information interoperability, data standardization, and advanced analytics
[10]. The studies that evaluate Industry 4.0 adaptation process especially in developing
countries are quite few. In this study, the perceptions and awareness of leading compa‐
nies in Turkey are evaluated in terms of operational and socio-economic factors, and
the readiness level scores are computed. The strengths and weaknesses of the companies
are revealed by checking the results of readiness evaluation and the barriers they can
face with are discussed. In the cases, three leading companies from construction, textile,
414 G. T. Temur et al.
and wire production industries are taken into consideration. In this pursuit, a detailed
questionnaire is conducted with their Industry 4.0 coordinators.
The rest of the study is organized as follows: Sect. 2 gives a brief information and
literature review for readiness level and Industry 4.0 readiness evaluation. Section 3
includes the Industry 4.0 awareness and readiness level evaluation methodology.
Section 4 illustrates conducting the readiness evaluation procedure for companies from
construction, textile and wire production sectors. Section 5 discusses the results briefly.
Section 6 presents the research results and further plan of the study.
In a system, the success of improvement of a new process is directly affected from the
prior performance of research and development (R&D) studies. The level of prior efforts
give foresight about the readiness of the system for new capabilities. In the Cambridge
dictionary, readiness is defined as “willingness or a state of being prepared for some‐
thing” [11]. The preparation for something is related with the prior effects. This term is
mostly used for technology adaptation and utilization process. Readiness evaluations
for technology are utilized to clarify the maturity of new capability requirements [12].
Evaluation consists of determination of performance goals, readiness level and hardness
degree of R&D studies. Mankins categorizes the technology readiness into 9 levels and
proposes a descriptive analysis of each level that begins from reporting basic principles
and ends with proving actual system [12]. Especially in high-tech environments, such
as Industry 4.0 development or adaptation processes, high importance is attached to
technology readiness level.
Technology readiness levels propose a measurement system, but it is also required
to develop a metric for determination of integration level. By the help of technology
readiness and integration readiness levels, the system maturity can be evaluated compre‐
hensively [13].
There are different readiness level measurements specified for different operations or
processes, such as Design Readiness Level, Manufacturing Readiness Level, Software
Readiness Level, and Operational Readiness Level [14]. After “Industry 4.0” is
announced as a new concept by German government in 2012, researchers have begun
to attach high importance to develop new metrics to measure the “Industry 4.0 Readiness
Level”. Industry 4.0 Readiness Level evaluations are a metric development and meas‐
urement process to check the maturity of related system’s technologies and infrastruc‐
ture before full adaptation is performed. In order to be ready for adapting Industry 4.0
necessities, some pre-conditions should be supplied [15] such as (1) standardization (of
systems, platforms, protocols, connections, etc.), (2) work organization, (3) availability
of products, new business models, know-how protections, and (4) availability of skilled
workers, research, professional development, legal framework. The readiness level of
Evaluation of Industry 4.0 Readiness Level 415
Industry 4.0 within companies can be measured by evaluation of these 4 items, but the
evaluation of readiness level differs regarding the perspective of the academics, practi‐
tioners and international consortia in the relevant domains. Most of the readiness and
maturity models are proposed for manufacturing industry, which is directly and dramat‐
ically affected by Industry 4.0 revolution. IMPULS model [16] consists of 6 evaluation
factors including strategy and organization, smart factory, smart operations, smart prod‐
ucts, data-driven services, and employees. Tonelli et al. (2016) propose another value
modelling and mapping for Industry 4.0 in which “Gartner Maturity Model” takes place
[17]. In this model, there are five stages including (1) reacting the firms focusing on
operations, (2) forecasting supply chain plans, (3) integrating the firms to the maturity
process, (4) collaborating the companies that catch the maturity, and (5) coordinating
the barriers between demand and supply. Schumacher et al. (2016) provide a maturity
level for evaluating the readiness of Industry 4.0 in terms of nine dimensions; strategy,
leadership, customers, products, operations, culture, people, governance and technology
[18]. They test the proposed model in many firms. Akdil et al. (2018) present other
maturity and readiness model that are consisted of three important dimensions such as
smart products and services; smart business processes; strategy and organization [19].
The dimensions are measured conducting surveys, which are graded by scores between
0 and 3 and by checking the scores. The maturity of firms are categorized into 4 parts,
such as absence, existence, survival, and maturity.
3 Methodology
• The awareness on the patents taken out by universities and techno parks on devel‐
opment of Industry 4.0
• The number of patents taken out by the company on Industry 4.0
• The percentage of Industry 4.0 investments in total annual investment
• The participation of the company to educational activities for development of
Industry 4.0
• The most important operations in which Industry 4.0 tools are utilized
• The opinion of the company on Industry 4.0’s effect on ethnic discrimination
• The opinion of the company on Industry 4.0’s effect on unemployment
• The opinion of the company on Industry 4.0’s effect on inequality of women and men
• The opinion of the company on Industry 4.0’s effect on income inequality
• The opinion of the company on Industry 4.0’s effect on social interaction
In the second part of the questionnaire, following questions are asked for evaluation
and computation of the readiness level by applying the IMPULS model:
Strategy and organization:
• The existence of a road map for Industry 4.0 adaptation process
• The existence of a new workforce planning for Industry 4.0 adaptation process
• The strategy development capability for Industry 4.0 adaptation process
• The attitude to improve process compliance in Industry 4.0
• The increase of investments on different operations
• The existence of corporate technology and innovation management capability
Smart factory:
• The capability on collecting the data
• The capability on using real time data for automatic production planning and control
• The reasons for using data
Smart operations:
• The capability on integration of the systems and machines
• The operations in which internal integration has been conducted
• The operations in which external integration has been conducted
• The existence of autonomous control
• The existence of internal data storage
• The security of internal data storage
• The security of cloud systems
• The security of data sharing with business partners
• The operations in which cloud systems are utilized.
Smart products:
• The Information and Communication Technologies add-on functionalities of products
Data-driven services:
• The position of the company on data driven services
• The share of data used in the company
Evaluation of Industry 4.0 Readiness Level 417
• The company does not believe that Industry 4.0 will increase unemployment.
• The company does not believe that Industry 4.0 will increase the inequality between
women and men.
• The company highly believes that Industry 4.0 will increase unequal distribution of
income.
• The company highly believes that Industry 4.0 will decrease social interaction.
The results show that the company believes that they are good in following the new
challenges, but they are not sufficient to act proactively. They are conservative in being
more competitive and innovative. The competitive pressure has direct impact on their
own Industry 4.0 adaptation process. Furthermore, the company has an optimistic idea
about the effect of Industry 4.0 on unemployment, but they believe that equal distribution
of income will be affected negatively.
For the evaluation of the readiness through the items of IMPULS model, it is assumed
that each of the evaluation factors has the same importance weight. In our case, there
are 24 factors (sa1 , sa2 , … , sa24 ); therefore each of them has the importance value 0.0416
(w1 = w2 = … = w24 = 0.0416). The total of importance weights is “1”. Under these
conditions, the readiness of the company (RC ) is evaluated by computing the weighted
average using the following formula:
w1 ∗ sa1 + w2 ∗ sa2 + … + w24 ∗ sa24
RC = (1)
w1 + w2 + … + w24
RC(construction) = 3.75
With the score of 3.75, the company can be accepted as an “experienced” company.
In order to demonstrate the readiness level of the company in terms of the six main
evaluation factors, a radar chart is prepared. As shown in Fig. 1, the readiness score in
terms of strategy and organization is very low as compared to others because the
company fails in improving a road map and new workforce planning. The second
important reason is that the company has not applied new strategies for Industry 4.0 yet.
Evaluation of Industry 4.0 Readiness Level 419
Strategy and
organization
5
4.5
4
3.5
3
Employees 2.5 Smart factory
2
1.5
1
0.5
0
Smart products
Fig. 1. Radar chart demonstrating the readiness of the construction company in terms of 6 main
factors
• In the company, the most important operation is production where Industry 4.0 tools
are used.
• The company believes that Industry 4.0 will not increase ethnic discrimination.
• The company believes that Industry 4.0 will not increase unemployment.
• The company believes that Industry 4.0 will not increase inequality of women and
men.
• The company believes that Industry 4.0 will not increase unequal distribution of
income.
• The company believes that Industry 4.0 will not decrease social interaction.
The results show that the company believes that they are aware of Industry 4.0
processes, but they do not have enough capability to act for implementing Industry
4.0 applications in all aspects. They seem that they are satisfied for being a good
follower, and by the effect of the market requirements and competitive pressure.
They have potential to act effectively on this issue in the near future. It is also inter‐
esting to notice that the company is very optimistic about the socio-economic effects
of Industry 4.0. Although textile industry is labour intensive and the digitalization
may have direct impact on the workforce, the company prefers to ignore such nega‐
tive outputs. This is probably because that the company does not have enough expe‐
rience in implementing real processes for Industry 4.0. Also, the company may
believe that new job opportunities can be increased, which might prevent dramatic
negative results on unemployment.
For the evaluation of the readiness through the items of IMPULS model, the same
assumptions provided in the previous case are accepted. By using Eq. (1), the readiness
score of the company is computed as follows:
0.0416 ∗ 0 + 0.0416 ∗ 0 + 0.0416 ∗ 0 + 0.0416 ∗ 0 + 0.0416 ∗ 2.16 + 0.0416 ∗ 1 + 0.0416 ∗ 4+
0.0416 ∗ 4 + 0.0416 ∗ 3.57 + 0.0416 ∗ 1.66 + 0.0416 ∗ 1.57 + 0.0416 ∗ 1.57 + 0.0416 ∗ 0 + 0.0416 ∗ 3+
0.0416 ∗ 4 + 0.0416 ∗ 3 + 0.0416 ∗ 3 + 0, 0416 ∗ 1.66 + 0.0416 ∗ 3.25 + .0416 ∗ 0 + 0.0416 ∗ 4+
0.0416 ∗ 0 + 0.0416 ∗ 2.33 + 0.0416 ∗ 3.57:
RC(textile) =
1
RC(textile) = 1.96
With the score of 1.96, the company can be accepted as a “beginner”. In order to
demonstrate the readiness level of the company in terms of six main evaluation factors,
a radar chart is constructed. As shown in Fig. 2, the readiness score in terms of strategy
and organization is very low as compared to others because the company fails in
improving a road map and new workforce planning. Besides that, it is stated that Industry
4.0 process does not affect the firm strategy; and the adaptability of the company to
Industry 4.0 has not been evaluated yet. Interestingly, there is no any new strategic
improvement in this company.
Evaluation of Industry 4.0 Readiness Level 421
Strategy and
organization
4.00
3.50
3.00
2.50
Employees 2.00 Smart factory
1.50
1.00
0.50
0.00
Smart products
Fig. 2. Radar chart demonstrating the readiness of the textile company in terms of 6 main factors
The second factor that has low score is data driven services. They do not share any
data with external stakeholders and not use any data driven system.
• In the company, the most important operations are logistics and production where
Industry 4.0 tools are used.
• The company believes that Industry 4.0 will not increase ethnic discrimination.
• The company believes that Industry 4.0 will not increase unemployment.
• The company believes that Industry 4.0 will not increase inequality of women and
men.
• The company believes that Industry 4.0 will moderately increase unequal distribution
of income.
• The company believes that Industry 4.0 will not decrease social interaction.
The results show that the company believes that they are interested in Industry 4.0
processes, but their capability is limited to only “being a follower”. The company is
optimistic about the socio-economic effects of Industry 4.0 except its effect on unequal
distribution of income. Contrasting to other companies, although it is a production
company, the investment on technology is low. In order to become the pioneer and leader
in Industry 4.0 applications, the percentage of Industry 4.0 investments in the total
annual investment should be increased.
For the evaluation of the readiness through the items of IMPULS model, the same
assumptions given in the previous case are accepted. By using Eq. (1), the readiness
score of the company is computed as follows:
0.0416 ∗ 0 + 0.0416 ∗ 0 + 0.0416 ∗ 2 + 0.0416 ∗ 3 + 0.0416 ∗ 1.66 + 0.0416 ∗ 2 + 0.0416 ∗ 4+
0.0416 ∗ 4 + 0.0416 ∗ 3.57 + 0.0416 ∗ 1 + 0.0416 ∗ 2.14 + 0.0416 ∗ 0 + 0.0416 ∗ 0 + 0.0416 ∗ 3+
0.0416 ∗ 3 + 0.0416 ∗ 3 + 0.0416 ∗ 3 + 0, 0416 ∗ 0 + 0.0416 ∗ 0 + .0416 ∗ 0 + 0.0416 ∗ 5+
0.0416 ∗ 3 + 0.0416 ∗ 3 + 0.0416 ∗ 4.14:
RC(production) =
1
RC(production) = 2.1
With the score of 2.1, the company can be accepted as a “beginner” company. In
order to demonstrate the readiness level of the company in terms of six main evaluation
ctors, a radar chart is used. As shown in Fig. 3, the readiness score in terms of smart
products is very low compared to others. Because there are not any information and
communication technologies add-on functionalities of products. Strategy and organi‐
zation and smart operations have also very low scores. The reasons are the same as the
other companies in terms of strategy and organization. However, for smart operations,
the reasons for low scores are (1) there is not any external integration among any oper‐
ations, (2) there is not any autonomous control, and (3) there is not any cloud system.
Evaluation of Industry 4.0 Readiness Level 423
Strategy and
organization
4.50
4.00
3.50
3.00
Employees 2.50 Smart factory
2.00
1.50
1.00
0.50
0.00
Smart products
Fig. 3. Radar chart demonstrating the readiness of the wire production company in terms of 6
main factors
6 Conclusion
This study aims to evaluate the perceptions and readiness levels of leading companies
on Industry 4.0 adaptation processes in Turkey. As a result of the evaluation process, it
is revealed that there is lack of motivation to be the pioneer and leader in Industry 4.0.
Hence, the companies tend to continue to be a “follower” in order to preserve their
current conditions under control. Although, they are conservative to apply new devel‐
opments in a short time, they believe that Industry 4.0 will have positive effects on socio-
economic conditions. Moreover, there is lack of consciousness and effort on new strategy
development. They have not prepared any road map and new workforce plans yet.
This study contributes by dealing with some cases in Turkey as an emerging
economy, considering the points of view and awareness on Industry 4.0 adaptation
process in such environment. This study also introduces readiness level measurement
applications for a developing country. In the future, the survey can be conducted with
many other companies to perform advanced statistical analysis. Furthermore, because
the scores are originated from the perceptions, which have subjectivity, fuzzy set theory
can be utilized for scoring. Moreover, rather than assuming that all weights are equal,
the importance of the evaluation factors can be computed by the help of decision making
tools such as analytical hierarchy process.
References