Industry 4.0 robotic automation in manufacturing: a normalisation process theory approach.

Abstract

The fourth industrial revolution (I4.0) is a key driver for technology innovations, with repeated claims that it will revolutionise manufacturing. Among its core enabling technologies, I4.0 robotic automation has emerged as key smart manufacturing technologies. However, despite their potential benefits, many manufacturers struggle with their successful implementation. One explanation for this is that realising benefits from these technologies depends on an effective innovation process, particularly implementation and post-implementation stages.

Prior studies exploring the I4.0 technology innovation process have often focused on specific aspects and/or single stages, neglecting a stage-based approach. Moreover, the technical underpinning of I4.0 has led to an emphasis on exploring wider I4.0 adoption, and implementation from a technical perspective- focusing on features of the technologies, design principles, or classifying I4.0 enabling technologies. Consequently, non-technical aspects of I4.0 technology implementation including organisational or social aspects have received less attention. Additionally, studies focusing on these aspects have been argued to present an inconsistent and fragmented picture of what implementation encompasses, while considerably less attention has been given to post-implementation stages. This relates to a critical knowledge gap considering that an innovation may be implemented but not necessarily sustained.

To address these gaps, this thesis explores the processes leading to the normalisation of I4.0 robotic automation. Adopting normalisation process theory (NPT), the thesis focuses on the stages of implementation and post-implementation (embedding and integration), with the aim of understanding how I4.0 robotic automation becomes normalised in manufacturing firms. This is achieved through a multiple case study of three UK manufacturing plants, based on 43 semi-structured interviews.

The thesis findings highlighted that normalising I4.0 robotic automation is an ongoing and dynamic transition requiring effort across organisational levels. Specifically, the findings emphasise the significance of social and psychological factors, highlighting the need for a human-centric approach. The findings suggest there is a need to extend NPT to increase its applicability in the I4.0 context. Psychosocial work is proposed as an additional construct, alongside three further subcomponents: external support, implementation approaches, and external influences. Acknowledgement of adoption drivers on the normalisation process, and the significance of “de-normalising” pre-existing routines is also suggested. Overall, successful normalisation requires engagement in understanding the purpose and value of the I4.0 robotic automation, relational work, operational work, psychosocial work, and adaptive work. Finally, the findings highlighted the critical role of relational and normative restructuring.

Thesis embargoed until  31 December 2030.

Date of Award	Dec 2025
Original language	English
Awarding Institution	Queen's University Belfast
Sponsors	Northern Ireland Department for the Economy
Supervisor	Sara Melo (Supervisor) & Byron Graham (Supervisor)