Dimitris Mourtzis

University of Patras Lab. For Manufacturing Systems and Automation (LMS) · Mechanical Engineering and Aeronautics

Manufacturing system design (MSD) plays a key role in improving product quality, production efficiency, and system sustainability. The individualized requirements for MSD are interconnected and coupled with each other, while the optimization process requires coordination among various system key performance metrics (Mourtzis, 2020; Gu et al., 2015)...

With the continuous development of human-centric, resilient, and sustainable manufacturing towards Industry 5.0, Artificial Intelligence (AI) has gradually unveiled new opportunities for additional functionalities, new features, and tendencies in the industrial landscape. On the other hand, the technology-driven Industry 4.0 paradigm is still in fu...

Modelling and Simulation (M&S) are critical capabilities for Cloud Computing. M&S products and services are valuable resources that have to be easily accessible and available on demand in a cost-effective way to users; they provide the required level of agility so that capabilities can be integrated quickly and easily. To address new design and man...

Companies operating in global production networks should handle the complex, uncertain, and volatile environment, making them more vulnerable to disruptions. The Mass Personalization (MPe) paradigm is already a reality and has increased the involvement of end-users in the product lifecycle. It requires responsive and flexible manufacturing operatio...

CFP SI: International Journal of Production Research. Resilient, Human-Centric, and Sustainable Manufacturing Systems towards Industry 5.0

The current industrial landscape is characterized by the immense effort towards the digitalization of systems, networks and processes. Under the light of Industry 4.0, digital technologies such as Digital Twins (DT), eXtended Reality (XR), and Additive Manufacturing (e.g. Fused Deposition Modeling – FDM) are considered among other key pillars for c...

A computer-aided numerical method for the design of a cam-follower mechanism and NC milling for a planar cam profile is presented. The method consists of an iteration method for the calculation of the follower motion properties (oscillation, velocity and acceleration, jerk) using the vector differences for three successive points on the cam profile...

In recent years, there has been a concerted effort to revolutionize industrial production through the integration of digital technologies, leading to the emergence of Industry 4.0 and to the upcoming fifth societal revolution (Society 5.0). Key technologies driving this revolution include, among others, artificial intelligence (AI), virtual/augment...

Despite the numerous benefits of additive manufacturing (AM), drawbacks like poor surface quality, dimensional accuracy, and internal stresses imply that AM-related techniques can rarely produce ready-to-use parts out of the machine. More often than not, AM parts need to be further processed regardless of their material in order to obtain a complet...

In the context of Industry 5.0, the concept of the Metaverse aligns with the vision of Web 4.0, representing a digital ecosystem where individuals and organizations collaborate in a human-centric approach to create personalized value. This virtual universe connects multiple interconnected worlds, enabling real-time interactions between users and co...

With the shift towards the human centric, sustainable, and resilient Industry 5.0, the need for training operators in complex industrial systems has become increasingly crucial. This paper explores the significance of collaborative extended reality (XR)-based engineering education in the preparation of the next generation of operators, denoted as O...

In recent years, the traditional manufacturing industry has been affected by the advent of Industry 4.0. Robotic systems have become a standard tool in modern manufacturing, due to their unique characteristics, such as repeatability, precision, speed, and high payload. However, robotics manipulators suffer from low reliability. Low reliability incr...

During the last decades numerous innovations and inventions have been presented under the framework of Industry 4.0. The ultimate goal of the latest industrial revolution is the digitalization of modern manufacturing systems. Therefore, several techniques and technologies have been investigated by the academia and the industrial practitioners, such...

Climate change, improved energy efficiency, and access to contemporary energy services are among the key topics investigated globally. The effect of these transitions has been amplified by increased digitization and digitalization, as well as the establishment of reliable information and communication infrastructures, resulting in the creation of s...

Recently, the emergence of various technological advancements has enabled the development of new and unique applications for industrial robots [...]

The evolution of the power grid towards a Smart Grid is a crucial aspect of the transformation of society towards the so-called Society 5.0, where human-centered technology is the key to address social challenges. This paper proposes a personalized service approach for Smart Grids within the Society 5.0 framework, which aims to provide a personaliz...

The blending of human and mechanical capabilities has become a reality in the realm of Industry 4.0. Enterprises are encouraged to design frameworks capable of harnessing the power of human and technological resources to enhance the era of Artificial Intelligence (AI). Over the past decade, AI technologies have transformed the competitive landscape...

Robotic systems have become a standard tool in modern manufacturing due to their unique characteristics, such as repeatability, precision, and speed, among others. One of the main challenges of robotic manipulators is the low degree of reliability. Low reliability increases the probability of disruption in manufacturing processes, minimizing in thi...

In the era of digital transformation, industry is facing multiple challenges due to the need for implementation of the Industry 4.0 standards, as well as the volatility of customer demands. The latter has created the need for the design and operation of more complex manufacturing systems and networks. A case study derived from Process Industries (P...

Digital Twins, as a technological pillar of Industry 4.0, correspond to the virtual representation and bi-fold a real-time communication of a digital counterpart of a process or a physical object. As the industrial and manufacturing landscape is shifting towards Industry 5.0, huge investments focusing on enhancing interactions between Operators and...

One of the core engineering activities during the design and development of new products, components, and structures is the structural simulation in order to validate the design and ensure that the parts will efficiently withstand the loading cycles. On the other hand, simulation is one of the nine pillar technologies for Industry 4.0. Under the cu...

The automation of workflows for the optimization of manufacturing processes through digital twins seems to be achievable nowadays. The enabling technologies of Industry 4.0 have matured, while the plethora of available sensors and data processing methods can be used to address functionalities related to manufacturing processes, such as process moni...

Modern manufacturing systems rely on the utilization of Computer Numerical Control (CNC) for the manufacturing of products and components. By extension, engineers must be capable of programming machine tools (through G-code) in order to achieve the desired results. However, this process is time consuming and requires highly skilled and trained pers...

Blockchain can be realized as a distributed and decentralized database, also known as a “distributed ledger,” that is shared among the nodes of a computer network. Blockchain is a form of democratized and distributed database for storing information electronically in a digital format. Under the framework of Industry 4.0, the digitization and digita...

Hybrid classrooms have become more and more common during the pandemic. Digital technologies have accelerated the transition into the university of the future. Digital Twins technology, one of the trending technologies related to Industry 4.0, helps faculty to create simulation models based on course requirements. Universities are still facing the...

The term “Metaverse” first used in Neal Stephenson's sci-fi book Snow Crash in 1992, refers to a fusion of virtual and real existence. Nearly 30 years later, that definition is taking shape and promises to alter how people live and operate. This next evolution of Internet also known as Web3.0 will combine digital and physical elements. Multiple def...

A significant shift from traditional lines to reconfigurable and reprogrammable robotic cells has occurred in Industry 4.0. Collaborative robots can be used for automating several tasks for improving Human-Machine Interface (HMI). The ability of a robot carrying out different tasks is proportional to the tools that it can use, thus it is crucial th...

During the past few years, industry has begun to recognize the operational and economic value of Unmanned Aerial Vehicles (UAVs) operations. Internet of Things (IoT), Augmented Reality (AR), UAVs etc. are being continuously applied within Industry 4.0 applications due to their major capabilities on the optimization of modern manufacturing concepts....

Drones have proven to be valuable tools in a variety of industries in recent years under the Industry 4.0 framework. Construction, real estate, agriculture, oil and gas, education, and many other industries are reporting fewer accidents, lower costs, and increased efficiency by integrating Unmanned Aerial Vehicles (UAVs) to their operations. Furthe...

Coordinating the digital transformation of globally dispersed factories within global manufacturing networks has become critical for competitiveness. From the procurement of raw materials to manufacturing and logistics, and finally to customer fulfillment, digitization is uniting a once siloed supply chain into an integrated end-to-end digital ecos...

Industry 5.0 blows the whistle on global industrial transformation. It aims to place humans' well-being at the center of manufacturing systems, thereby achieving social goals beyond employment and growth to provide prosperity robustly for the sustainable development of all humanity. However, the current exploration of Industry 5.0 is still in its i...

This special session aims to present the state-of-the-art approaches, tools, systems, and practical cases of HDT toward HCPS, including the following topics, but are not limited to: • Theory, investigation, survey, and review of HDT for HCPS • HDT in Human-Robot Collaboration (HRC) • Big data analytics for HDT • Data management and data policies in...

Manufacturing has been hugely affected by the COVID-19 pandemic, with many critical global value chains either halted or seriously interrupted. Most interactions with customers and employees have to take place in a contactless or virtual way. As such, digital operation is the way to remain in business through mandatory shutdowns and restricted acti...

By virtue of the increased automation, digitization, and digitalization of manufacturing and production systems a constantly growing amount of data, also known as Big Data Sets, are produced. Thus, techniques, in particular Machine Learning (ML) and Artificial Intelligence (AI), to utilize and organize Big Data Sets for the benefit of contemporary...

In the era of Industry 4.0, manufacturing and production systems were revolutionized by increasing operational efficiency and developing and implementing new business models, services, and products. Concretely, the milestone set for Industry 4.0 was to improve the sustainability and efficiency of production systems. By extension, the emphasis was f...

Chatter is an uncontrollable and unattenuated vibration that results in large oscillations between the workpiece and the cutting tool and has a detrimental effect on the surface quality, the tool life and the health of the machine tool components. As a result, it is one of the key limitations that hinders the productivity and quality of the milling...

Recently, the futuristic industry and society have caught increasing attention, that is, on Industry 5.0 and Society 5.0. Industry 5.0 is announced by European Commission toward a sustainable, human-centric, and resilient European industry. Society 5.0 is proposed by Japan Cabinet to balance economic advancement with the reso�lution of social probl...

Manufacturing and Production Industries are currently being reshaped to integrate the new Information and Communication Technologies (ICT) in the existing workplaces. Industry 5.0 is a value-driven approach and is based on three interconnected core pillars: 1) human-centricity, 2) sustainability, and 3) resilience. However, it is necessary to fully...

The shift of traditional mass-producing industries towards mass customisation practices is nowadays evident. However, if not implemented properly, mass customisation can lead to disturbances in material flow and severe reduction in productivity. Moreover, manufacturing enterprises often face the challenge of manufacturing highly customized products...

This keynote paper mainly focuses on advancements of machining technology and systems for enhanced performance, increased system integration and augmented machine intelligence, critically hinging on new sensors, sensor systems and sensing methodologies being robust, reconfigurable and intelligent, while providing direct adoption and plug-and-play u...

Modern manufacturing and production companies have transformed their business models in order to integrate Product-Service Systems (PSS). These changes in the modus operandi of companies facilitates the close collaboration of manufacturers and customer in the development of new product. Furthermore, the recent research works in the field of simulat...

Over the last decade, Industry 4.0 has focused more on digitalization and AI-driven technologies for increasing the efficiency and flexibility of production. In early 2021, the European Commission proposed the concept of “Industry 5.0”, which complements the existing “Industry 4.0” paradigm. However, since the European Commission released its Indus...

Manufacturing systems have undergone many changes with regard to their structure, organization, and operation. This chapter charts the technical developments in manufacturing systems over the last 70 years. The basic building blocks of Computer-Aided Manufacturing and their evolution to Computer-Integrated Manufacturing systems are discussed. We de...

In the realm of the fourth industrial revolution, the flawless and continuous operation of the technology-rich workplaces is a challenging problem. The assessment of technician skills could facilitate initially the personnel classification, and in continuation the adaptation of guidance instructions as well as the job allocation to their unique att...

Under the framework of Industry 4.0, machines and machine tools have evolved to smart and connected things, comprising the Internet of Things (IoT) and leading to the Mass Per-sonalization (MP) paradigm, which enables the production of uniquely made products at scale. MP, fueled by individualization trends and enabled by increasing digitalization,...

Robotic manipulators have become part of manufacturing systems in recent decades. However, in the realm of Industry 4.0, a new type of manufacturing cell has been introduced—the so-called collaborative manufacturing cell. In such collaborative environments, communication between a human operator and robotic manipulators must be flawless, so that sm...

In today's business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production systems as well as to choose the optimal product matches, product analys...

The industrial landscape is undergoing a series of fundamental changes, because of the advances in cutting-edge digital technologies. Under the framework of Industry 4.0 engineers have focused their effort on the development of new frameworks integrating digital technologies such as Big Data Analytics, Digital Twins, Extended Reality, and Artificia...

Resistance spot welding for industrial applications is a fully automated process which however lacks this aspect when it comes to quality assessment (QA). The current study introduces an online QA approach that utilizes machine learning methods, on data captured from an infrared (IR) camera, mounted on an RSW-robotized system. The models’ developme...

Over the past decades, automation industry has seen a major shift from traditional, hard-tooled lines to reconfigurable and reprogrammable robotic cells. Robots have added increasing value to the industry with special focus on robotic arms which enable many repetitive tasks to be carried out with high repeatability, reliability, flexibility, and sp...

The digital twin is now within reach while manufacturing and manufacturing process become increasingly digital and the Internet of Things (IoT) is becoming more and more dominant. Digital twins are intended to model complex structures and processes that communicate with their environments in various ways, for which it is challenging to predict effe...

During the last decades numerous innovations and inventions have been presented under the framework of Industry 4.0. The ultimate goal of the latest industrial revolution is the digitalization of modern manufacturing systems. Therefore, several techniques and technologies have been investigated by the academia and the industrial practitioners, such...

Following the concepts introduced by Industry 4.0, manufacturing sector is moving towards digitalization, supported by advanced manufacturing technologies. Despite globalization and easy access to information, digitalization has not advanced in a similar way among different countries, but also within the industries of the same country. According to...

Simulation, as a pillar technology of Industry 4.0, is a key tool for improving manufacturing processes. Simulation is an indispensable set of technological tools and methods for the successful implementation of digital manufacturing, since it allows for the experimentation and validation of product, process, and system design and configuration. Th...

Modern manufacturing environments strive to support a great variety of products, driven by the large customization demand, while at the same time maintain low cost and fast response to the market. To cope with the challenging manufacturing requirements, organizations rely on agile decision-making systems to maintain a smooth production function. In...

According to the recent enactments of the European authorities, the reduction of CO2 emissions is one of the main targets, in order to achieve climate neutrality. However, under the Industry 4.0 framework, several digital technologies and techniques have been introduced. More specifically, advanced simulation techniques, such as Digital Twins are b...

Aim: This work explores the opportunities and challenges associated with the integration of Product Service Systems (PSS) into Smart Grids (SGs) with the aim of improving manufacturing and production systems’ sustainability under the Society 5.0 framework. Methods: A bibliometric analysis was conducted to examine the existing bibliographic material...

For many applications deployed in manufacturing networks, communication latency has been a significant barrier. Despite the constant development of improved communication protocols and standards during Industry 4.0, the latency problem persists, lowering quality of services (QoS) and quality of experience (QoE). Tactile internet (TI), with its high...

The paradigm shift from mass production to on-demand, personalized, customer-driven, and knowledge-based production reshapes manufacturing. Smart manufacturing leads to an automated world that relies more on information and communication technologies (ICTs) and sophisticated information-technology-intensive processes, enhancing flexibility. Further...

The industrial Internet of things (IIoT) key technologies advance flexibility, personalization, and cost savings in industrial processes. Smart manufacturing and Industry 4.0 integrate the physical and decision-making aspects of manufacturing processes into autonomous and decentralized systems. Cloud manufacturing is emerging with scheduling issues...

The mass personalization (MP) paradigm increases end user engagement in the manufacturing process. Moreover, manufacturers aim to remain competitive, while they also build trust with their clients and gain insights into their preferences. The increasing need for personalized products, in combination with the volatile market demand, affect industrie...

In recent decades, globalization has led to profound changes in the economy (Dicken, 2007; Lanza et al., 2019). Nowadays, companies of any size operate worldwide in the form of global production networks (GPNs). GPNs are one of the manufacturing industry’s most critical forms of organization (Yeung & Coe, 2015) and already account for almost 80% of...

New technologies such as Unmanned Aerial Vehicles (UAV) are constantly being introduced under the Industry 4.0 framework. Although UAVs are mainly used in civil and military applications, the opportunities for Industrial integration must be examined, namely real-time remote monitoring, wireless coverage, and remote sensing. Therefore, UAVs can be c...

The digitalization of modern manufacturing systems has resulted to increasing data generation, also known as Big Data. Although there are several technologies and techniques under the term Data Analytics for gathering such data, their interpretation to information, and ultimately to knowledge remains in its infancy. Consequently, albeit engineers,...

As the industrial requirements change rapidly due to the drastic evolution of technology, the necessity of quickly investigating potential system alternatives towards a more efficient manufacturing system design arises more intensely than ever. Production system simulation has proven to be a powerful tool for designing and evaluating a manufacturin...

The demand response monitoring is one key energy-efficient production technique and can reduce costs contributing simultaneously to the reduction of environmental emissions and maintaining the stability of electrical grids following the policies examined from European and International organizations. Although, energy trade market effect has been in...

The evolution of production systems encloses continuous adaptation of workplaces with changing levels of technologies and automation. This research paper examines scenarios of multi-skilled operators, cooperating to accomplish a common goal. The under-consideration environment consists of a distributed network of workstations, each one assigned wit...

The shift of profit margins from products to services, has transformed traditional production equipment supplier industries to providers of Industrial Product-Service Systems (IPSS). IPSS is a new business model for consistent delivery of industrial products such as production equipment and manufacturing services (Manufacturing as a Service). Howev...

A digitalized Smart Factory can be considered as a data island. Moreover, engineers have focused on the development of new technologies and techniques not only for transforming information to data but also to achieve efficient data utilization to further optimize manufacturing processes. However, the Zero-Defect Manufacturing concept has emerged, w...

Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) can be considered as the cornerstones of the lifecycle of a manufacturing asset. Since the above-mentioned processes often involve multiple engineers, from different departments even from different companies, it is crucial to ensure the flawless communication between the different i...

The research work presented in this paper is related to the design and development of a framework based on the Blockchain technology for the upscaling of modern academic education. The goal is to securely and successfully connect the multiple stakeholders involved in the academic education, including students, universities, research organizations a...