A Method for Performing Forging Operation: A Perspective of Industry 4.0

Background: Cold forging operation is done on small as well as large scale in manufacturing industries. These industries are facing problems such as higher rejection rate of the final product, low productivity, the high number of accidents during production, etc. Objective: The purpose of this research work is to develop a Voice-Assisted Forging System (VAFS) with a lower rejection rate, higher productivity, and lower number of accidents during production. Methods: Based on recently published journals and patents, traditional and automatic forging operations, Industry 4.0, and voice assisted systems are reviewed and VAFS is designed and developed. Then, the trial is taken on VAFS to investigate its performance. Finally, limitations and future research of the VAFS are proposed. Results: It is found that after implementation of the VAFS the average rejection count is reduced by 90.3 percentage, the operational productivity is increased by 71.2 percentage, and process accuracy is increased from 92.75 percentage to 99.30 percentage. Also, the number of accidents is reduced to zero. In comparison with the manual forging operation, the VAFS occupies less space, and it is easy to operate. Conclusion: This system will help the workers as well as the owner of industries to create a better man and machine relationship and to have a human-friendly working environment. VAFS reduces exhaustion and hassle of employees, components rejection, and energy consumptions in the production line.