Lights-out manufacturing concept in industry 4.0 process and IoT-based remote control of robot arm

The Industry 4.0 process today introduces innovative technologies that support energy efficiency, reduction of operational costs, and sustainable development goals through the digital transformation of production and industrial automation. The concept of dark factories is based on minimizing human intervention by employing technologies such as the Internet of Things (IoT), artificial intelligence, big data, and cyber-physical systems in production environments. These innovative approaches aim to ensure efficient use of resources and reduce environmental impacts. This study addresses IoT-supported remote control mechanisms by developing a robotic arm prototype based on ESP32. The robotic arm is designed as a system capable of receiving commands via Wi-Fi and providing precise servo motor control. The designed system offers an innovative solution to optimize energy efficiency, reduce operational costs, and automate production processes. This prototype, with potential applications in smart factories, provides flexibility, speed, and efficiency in production lines. Additionally, the smart city approach constitutes a significant aspect of this study. Smart cities enhance energy efficiency and support sustainable urban transformation through infrastructures equipped with IoT technologies. In this context, traffic management, energy consumption, and environmental impacts are controlled through data analytics, big data, and digital signaling systems. Smart city policies enable transformations in various areas, from urban planning to infrastructure management, offering forward-looking solutions. The main objective of this study is to present the technical design and implementation processes of an IoT-supported robotic arm prototype in the interaction of Industry 4.0 and smart city policies and to evaluate the impacts of these technologies in terms of energy efficiency, cost reduction, and sustainability. Accordingly, the project makes a significant contribution to increasing the automation levels of dark factories and sheds light on modern industrial applications.