Liangwei Zhang

Jay Lee, Hanqi Su, Marco Macchi et al.

The evolution of artificial intelligence (AI) and machine learning (ML) is reshaping smart manufacturing by providing new capabilities for efficiency, adaptability, and autonomy across industrial value chains. However, the deployment of AI and ML in industrial settings still faces critical challenges, including the complexity of industrial big data, effective data management, integration with heterogeneous sensing and control systems, and the demand for trustworthy, explainable, and reliable operation in high-stakes industrial environments. In this roadmap, we present a comprehensive perspective on the foundations, applications, and emerging directions of AI and ML in smart manufacturing. It is structured in three parts. The first highlights the foundations and trends that frame the evolution of AI in smart manufacturing. The second focuses on key topics where AI is already enabling advances, including industrial big data analytics, advanced sensing and perception, autonomous systems, additive and laser-based manufacturing, digital twins, robotics, supply chain and logistics optimization, and sustainable manufacturing. The third section explores non-traditional ML approaches that are opening new frontiers, such as physics-informed AI, generative AI, semantic AI, advanced digital twins, explainable AI, RAMS, data-centric metrology, LLMs, and foundation models for highly connected and complex manufacturing systems. By identifying both opportunities and remaining barriers across these areas, this roadmap outlines the advances needed in methods, integration strategies, and industrial adoption. We hope this roadmap will serve as a guide for researchers, engineers, and practitioners to accelerate innovation, align academic and industrial priorities, and ensure that AI-driven smart manufacturing delivers reliable, sustainable, and scalable impact for the future of manufacturing ecosystems.

Janet, Lin, Liangwei Zhang

This chapter bridges technical analysis and organizational preparedness by tracing the path from layered failure modes to reliability awareness in generative and agentic AI systems. We first introduce an 11-layer failure stack, a structured framework for identifying vulnerabilities ranging from hardware and power foundations to adaptive learning and agentic reasoning. Building on this, the chapter demonstrates how failures rarely occur in isolation but propagate across layers, creating cascading effects with systemic consequences. To complement this diagnostic lens, we develop the concept of awareness mapping: a maturity-oriented framework that quantifies how well individuals and organizations recognize reliability risks across the AI stack. Awareness is treated not only as a diagnostic score but also as a strategic input for AI governance, guiding improvement and resilience planning. By linking layered failures to awareness levels and further integrating this into Dependability-Centred Asset Management (DCAM), the chapter positions awareness mapping as both a measurement tool and a roadmap for trustworthy and sustainable AI deployment across mission-critical domains.