A Review of Recent Advanced Applications in Smart Manufacturing Systems

Smart Manufacturing Systems (SMSs) have evolved into intelligent, data-driven ecosystems that integrate cyber–physical systems, digital twins, and artificial intelligence to enhance efficiency, sustainability, and resilience. This review synthesises more than 250 recent studies across four domains: manufacturing technologies, systems management, sustainable production, and human–robot collaboration. In process optimisation, hybrid machine learning and genetic algorithms reduce surface roughness in machining by up to 35% and decrease energy use in additive manufacturing by 20–30%. In systems management, digital twins and reinforcement learning enable adaptive scheduling and predictive maintenance, increasing operational flexibility and reducing industrial downtime. Sustainability-oriented research shows that additive manufacturing can cut energy consumption by up to threefold compared with subtractive routes, while aluminium recycling and hot-forming processes lower life-cycle impacts. Furthermore, the integration of ISO 14001, ISO 50001, and ISO 14040 supports consistent environmental and energy performance assessment across sectors. Building on this evidence, the review critically examines recent developments in manufacturing technologies, systems management, sustainable practices, and human–robot collaboration, highlighting emerging paradigms such as explainable AI and human-centric design that strengthen safety, transparency, and resilience. Open challenges and research opportunities are outlined to guide future innovation toward intelligent, adaptive, and sustainable manufacturing systems.