Workforce and supply chain disruption as a digital and technological innovation opportunity for resilient manufacturing systems in the COVID-19 pandemic

https://doi.org/10.1016/j.cie.2022.108158Get rights and content

Highlights

  • COVID-19 impacts on the workforce and supply as an innovation opportunity.

  • Exploiting the potential of Human Cyber-Physical Production System in a pandemic.

  • Defining the Plug-and-play worker, Remote Operator 4.0 and Predictive Health of Operational Staff.

  • Fostering digital sourcing (i.e. additive manufacturing) and product/process innovation.

  • Lessons learned from prototype development and real world business examples are discussed.

Abstract

During the SARS-CoV-2 pandemic (also known as COVID-19), workforce downsizing needs, safety requirements, supply chain breaks and inventory shortages affected manufacturing systems’ and supply chain’s responsiveness and resilience. Companies wandered in a disrupted scenario because recommended actions/strategies to survive – and thrive – were not available an improvised actions to keep their operations up and running. This paper analyzes the COVID-19 impacts on the workforce and supply resilience in a holistic manner. The following research questions are discussed: (i) how can manufacturing firms cope with urgent staff deficiencies while sustaining at the same time a healthy and safe workforce in the perspective of socially sustainable and human-centric cyber-physical production systems?; (ii) is remote working (cf. smart working) applicable to shop-floor workers?; (iii) is it possible to overcome supply chain breaks without stopping production?

In the first part, we propose three Industry 4.0-driven solutions that would increase the workforce resilience, namely: (i) the Plug-and-Play worker; (ii) the Remote Operator 4.0; (iii) the Predictive Health of the Operational Staff. In the second part, the concepts of (i) Digital & Unconventional Sourcing, i.e. Additive Manufacturing, and (ii) Product/Process Innovation are investigated from a novel business continuity and integration perspective. We ultimately argue that forward-looking manufacturing companies should turn a disruptive event like a pandemic in an opportunity for digital and technological innovation of the workplace inspired by the principles of harmonic digital innovation (that places the human well-being at the center). These aspects are discussed with use cases, system prototypes and results from research projects carried out by the authors and real-world examples arising lessons learned and insights useful for scientists, researchers and managers.

Keywords

COVID-19 pandemic
Resilience
Manufacturing systems
Supply chain disruption
Digitalization
Industry 4.0
Additive manufacturing
Operator 4.0

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1

Ponte Pietro Bucci, Cube 45C, Third Floor – University of Calabria, Arcavacata di Rende (CS) 87036, Italy.

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