Development of an Integrated Intelligent Manufacturing System Utilizing IoT and Data Mining for the Digital Transformation of Industry 4.0

Resumo

The advancement of Industry 4.0 has driven digital transformation in manufacturing environments, promoting greater integration between machines, processes, and teams through smart technologies. In this context, this paper proposes the development and implementation of an integrated smart manufacturing platform based on Artificial Intelligence (AI), the Internet of Things (IoT), and Data Mining, aiming to optimize production processes and enhance the digital maturity of the company that manufactures bumper strips: Guillotine, Crease Cutting, Rewinder, and Reflective Film (Slitter). The main objective is to integrate systems, automate data collection, and enable real-time monitoring, predictive maintenance, and support for autonomous decision-making on the factory floor. The materials and methods involve detailed mapping of production processes, identification of bottlenecks, and definition of strategic points for installing IoT sensors on 11 cutting machines (side strip). The system architecture consisted of sensors, microcontrollers, gateways, a database, APIs, and interactive dashboards, integrated with existing corporate systems such as ERP and R&D Core. Data mining and machine learning techniques were applied for pattern analysis, anomaly detection, and prediction of operational failures. In addition, the system was validated in a real manufacturing environment, followed by training for the teams involved. As the results were effective in practice, they demonstrated greater operational efficiency, reduced waste, improved quality, increased traceability, and faster decision-making. It can be concluded that the implementation of the platform will contribute significantly to the consolidation of smart manufacturing, providing cyber-physical integration, greater industrial competitiveness, and a solid foundation for continuous innovation and future expansion of the solution in light of the maturity level of Industry 4.0.