Ingenious Island Manufacturing System (I²MS): A Sustainable and Digital Manufacturing Paradigm for Productivity, Circularity, and Low-Carbon Automotive Production

Abstract

The car industry is moving toward greater personalization, electrification, and sustainability, but traditional linear assembly lines lack flexibility, adaptability, and durability. This conceptual research introduces the Ingenious Island Manufacturing System (I²MS), which combines an island-based manufacturing paradigm with a Sustainable Digitalized Manufacturing System (SDMS). I²MS is a network of autonomous manufacturing islands that use robotics, cobots, Autonomous Mobile Robots (AMRs), IIoT sensors, and digital twins for predictive control. Each island is connected digitally by edge computer nodes and optimized for energy, emissions, and material tracking using sustainability modules. A centralized SDMS platform manages production, ensuring real-time decision-making and complete traceability. The full adoption of I²MS significantly improve the output capacity by increasing productivity as compared to the traditional baseline. An improvement in quality stability by the decrease in defect probability and CO2 emissions are lowered in every manufacturing cycle may be achieved. The optimization may beneficial in greatly increasing initial throughput, even though the advantages became less consistent in subsequent cycles. The Island-based smart manufacturing not only closes efficiency and flexibility gaps, but it also has substantial environmental and economic benefits. The suggested I²MS offers a scalable approach to resilient, adaptive, and sustainable vehicle production that aligns with Industry 5.0 objectives.