Workplace Safety in Industry 4.0 and Beyond: A Case Study on Risk Reduction Through Smart Manufacturing Systems in the Automotive Sector

Abstract

An important step toward automation and digitization in Industry 4.0 is the automobile sector’s use of smart manufacturing integrated systems (SMISs). Although this change increases productivity and competitiveness, it also creates new hazards for workplace safety. Key issues include ergonomic and cognitive strain from greater human–machine interactions, particularly with collaborative robots (cobots), and cybersecurity threats from the IIoT and cyber–physical systems. This paper looks at these hazards and stresses the value of safety precautions like predictive maintenance, traceability, and real-time monitoring. This case study investigates how the integration of smart manufacturing integrated systems (SMISs) and cyber–physical systems (CPSs) within Industry 4.0 frameworks enhances workplace safety in the automotive sector. Through a comprehensive case study of the final assembly line, this research explores how these technologies contribute to predictive maintenance, real-time monitoring, and human–machine collaboration, leading to significant reductions in ergonomic and cybersecurity risks.