Industry 4.0 implementation model for the composite manufacturing industry. Case for UK

<p dir="ltr">This doctoral thesis investigates the critical role of Industry 4.0 technologies in transforming the UK composite manufacturing sector, where reliance on manual processes, variable quality, and labour-intensive knowledge transfer present significant challenges. Industry 4.0 offers promising advancements for improving operational efficiency, scalability, and automation within this sector. However, the unique complexities of composite manufacturing, especially for Small and Medium Enterprises (SMEs), require a customised approach to digital integration. This research aims to address these needs by developing a structured, adaptable framework for Industry 4.0 adoption tailored specifically to the composites industry.</p><p dir="ltr">The study employs a demonstrator-centered research methodology, beginning with an extensive literature review to identify industry-specific challenges, opportunities, and knowledge gaps in Industry 4.0 applications. An industry-wide survey then assesses the current state of digital readiness within UK composite manufacturers, identifying key readiness factors and barriers to adoption. Insights from the literature and survey inform the design of a bespoke Industry 4.0 implementation framework, grounded in the systems engineering V-model. This framework provides a phased approach to digital transformation, addressing the integration of cyber-physical systems, workforce adaptation, and risk management strategies. Validated through a practical case study, the framework demonstrates its potential to guide composite manufacturers from manual to digital processes effectively.</p><p dir="ltr">The contributions of this thesis are twofold: (1) a validated, practical framework supporting composite manufacturers in the progressive adoption of Industry 4.0 technologies to enhance flexibility, automation, and operational efficiency; and (2) the introduction of demonstrators as vehicles bridging academic insights and industrial practice, showcasing the real-world applicability of theoretical models. Demonstrators across areas such as process automation, digital control, and real-time monitoring validate the framework's effectiveness and highlight the importance of strategic planning, stakeholder engagement, and iterative assessment for sustainable transformation.</p><p dir="ltr">This research ultimately offers a scalable roadmap for Industry 4.0 adoption in composite manufacturing, providing industry-specific insights to support standardisation and best practices in digital integration. The findings contribute to a broader understanding of Industry 4.0’s role in complex manufacturing contexts and serve as a foundation for future research into expanding automation for new composite materials, enhancing cyber-physical security, and developing robust implementation models across diverse manufacturing disciplines.</p>