An Industry 4.0 Framework for the Smart Production Management of Renewable Energy and Water Systems: An Application of AI, IoT, and Digital Twin Technologies
Mukhitdinov O. Jumanazarov D. Khudoynazarov E. Safarova L. Sakhabayeva S. Alsayah A.M.
1 December 2025University of Novi Sad
International Journal of Industrial Engineering and Management
2025#16Issue 4428 - 443 pp.
This study develops an integrated Industry 4.0 framework for smart production management in renewable energy systems applied to water processes. The framework combines artificial intelligence, the Internet of Things, and digital twin technologies to improve production planning, system reliability, and environmental performance. A neural network model was implemented for predictive analytics and achieved high accuracy (MAE = 0.82, R2 = 0.92), enabling precise forecasting for energy generation and operational scheduling. Optimization algorithms, including genetic algorithms and particle swarm optimization, increased energy utilization efficiency from 65% to 85% and reduced operational costs by 15%. The IoT utilization enhanced real-time monitoring and reduced fault detection time from 120 minutes to 15 minutes, significantly improving maintenance response. Digital twin simulations allowed process optimization and predictive maintenance, further increasing production efficiency to 92% and system uptime to 99.5%. The approaches also led to a 20% reduction in CO2 emissions, demonstrating both economic and environmental benefits. Overall, this framework offers a practical and data-driven solution for improving the efficiency and sustainability of renewable energy systems in water applications and contributes to the advancement of smart manufacturing in industrial engineering.
Digital twin technology , Industry 4.0 , Internet of things (IoT) , Machine learning (ML) , Optimization algorithms , Smart manufacturing
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Kimyo International University in Tashkent, Shota Rustaveli str. 156, Tashkent, 100121, Uzbekistan
Urgench State University, Kh. Alimdjan str. 14, Urgench, 220100, Uzbekistan
Mamun University, Bolkhovuz Street 2, Khiva, 220900, Uzbekistan
New Uzbekistan University, Movarounnahr street 1, Tashkent, 100000, Uzbekistan
Samarkand State University of Veterinary Medicine, Livestock and Biotechnologies, Samarkand, 140103, Uzbekistan
Advanced Research and Technology group» LLP, Astana, Kazakhstan
Refrigeration & Air-condition Department, Technical Engineering College, The Islamic University, Najaf, Iraq
Kimyo International University in Tashkent
Urgench State University
Mamun University
New Uzbekistan University
Samarkand State University of Veterinary Medicine
Advanced Research and Technology group» LLP
Refrigeration & Air-condition Department
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