Identifying Challenges and Ranking Strategies for the Implementation of Industry 4.0 Technologies

Introduction and Purpose: The Fourth Industrial Revolution, commonly known as Industry 4.0, has catalyzed significant transformations in production methodologies and maintenance systems. Nonetheless, the adoption and effective utilization of these technologies within Iran's steel industry encounter various challenges. This study aims to identify and analyze the obstacles associated with the implementation of Industry 4.0 technologies at the Isfahan Mobarakeh Steel Company, particularly focusing on the maintenance and repair department.
Methodology: In contrast to prior research that primarily offered general overviews of Industry 4.0 technologies or assessed organizational readiness for their implementation, this study specifically investigates the challenges associated with the adoption of these technologies at Mobarakeh Steel Company. Furthermore, it emphasizes the development of strategies to mitigate these identified obstacles. The statistical population for this study consists of ten experts from Mobarakeh Steel Company in Isfahan and its affiliated enterprises. Given the specialized nature of the research topic, participants were selected using purposive sampling.
This research employs a combination of qualitative and quantitative data analysis methods, including the fuzzy Delphi method, the Best-Worst Method (BWM), and the Quality Function Deployment (QFD) matrix. The primary objective is to identify and prioritize critical challenges related to digital transformation and to propose effective and practical strategies for addressing these issues. The challenges identified underscore the complexity of the transition and highlight the need for targeted interventions.
Finding : In the initial phase of this research, 31 identified challenges were systematically categorized into nine primary dimensions. These dimensions encompass: technical and technological challenges; organizational and managerial challenges; human and educational challenges; economic and political challenges; data and cybersecurity challenges; environmental challenges; supply chain challenges; cultural and social challenges; and research and development challenges.
The research findings reveal that several obstacles significantly hinder the implementation of Industry 4.0 technologies within the maintenance and repair sector. Key challenges include outdated and inefficient infrastructure, elevated costs necessitating substantial investments, a shortage of skilled labor, limitations imposed by international sanctions, complexities in supply chain management, and cybersecurity concerns. In response to this analysis, 13 strategic initiatives were refined and prioritized to address these challenges. These strategies include localizing technologies, developing a digital transformation roadmap, fostering a culture of Industry 4.0 across all organizational levels, conducting small-scale technology pilots, utilizing artificial intelligence for process management and optimization, and establishing collaborative networks among universities, research centers, and industries. The effectiveness of these strategies in mitigating the identified challenges was evaluated using the Quality House Matrix.
Discussion and Conclusion: Infrastructure, investment, human resources, and supply chain coordination challenges are significant obstacles to the digital transformation of the steel industry. Among these, outdated and inefficient infrastructure has been identified as the most pressing issue, underscoring the necessity for a comprehensive review of existing systems and the modernization of equipment. This indicates that in order to keep pace with digital transformation, the steel industry must develop advanced infrastructure capable of supporting emerging technologies. Furthermore, international sanctions and restricted access to advanced technologies are also notable barriers to the implementation of Industry 4.0 technologies. These challenges have imposed substantial limitations on access to modern equipment and software, thereby impeding progress towards digital transformation. The technologies associated with Industry 4.0 heavily rely on modern tools and software, the production of which necessitates advanced knowledge and expertise. Consequently, the imposition of sanctions and the reliance on foreign suppliers have posed significant challenges for domestic industries. This situation underscores the need for the localization of technologies and the enhancement of domestic production capabilities as strategic priorities. Additionally, the scarcity of skilled labor in emerging technologies, particularly in critical sectors such as maintenance and repair, constitutes another obstacle that could hinder the adoption of digital innovations. Given the complexity of Industry 4.0 technologies and the requisite high levels of technical proficiency, the absence of a specialized workforce restricts organizations' capacity to effectively implement these technologies.The strategies were analyzed using the Quality House Matrix, and their effectiveness in addressing the identified challenges was assessed. The strategies identified in this research offer specific solutions to address the challenges associated with the implementation of Industry 4.0 technologies. The development of a strategic roadmap serves as a tool for precise and targeted guidance of digitalization processes, enabling organizations to allocate resources optimally and mitigate confusion during the implementation stages. Establishing a digital innovation ecosystem represents a crucial strategy that underscores the significance of collaboration among industries, academic institutions, and knowledge-based enterprises. Furthermore, by formulating and executing policies related to cyber defense and data security, organizations can effectively address both internal and external threats that may compromise the security of information systems and sensitive data, thereby mitigating potential risks and damages.