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A large number of organisations are moving towards adopting Industry 4.0 (I4.0), and simultaneously, the emphasis on attaining sustainability development goals is also increasing. Hence, it is imperative to understand the interplay between I4.0 and sustainability. However, the literature addressing the same is still in infancy. Accordingly, the purpose of this study is to fill this gap in the literature by exploring the potential sustainability impacts of I4.0 on the organisations and society in terms of sustainability risks.

To gain an understanding of sustainability aspects in the I4.0 context, relevant literature is gathered using Scopus and Web-of-Science database. An in-depth review of 51 research papers is performed to determine the sustainability risks associated with I4.0.

From the study, a total of 16 sustainability risks are identified, and I4.0 sustainability risk taxonomy is developed. The proposed taxonomy extends the sustainability implications of I4.0 beyond the triple bottom line umbrella and includes the organisational perspective as well. Furthermore, the study provides future research avenues to scholars by positing five potential research questions under different risk management stages.

The study provides an understanding of sustainability risks associated with the adoption of I4.0. The findings will help practitioners streamline their production and operation processes by finding out possible solution to the sustainability risks of their smart factories in advance. The present research will act as a stepping stone towards I4.0 sustainability. The proposed research questions will assist the future researchers in extending the field of I4.0.

To the best of the authors’ knowledge, this is one of the first studies to address the topic of sustainability risks in the context of I4.0.

The paper aims to identify a suitable generic brake force distribution ratio (β) corresponding to optimal brake design attributes in a diminutive driving range, where road conditions do not exhibit excessive variations. This will intend for an appropriate allocation of brake force distribution (BFD) to provide dynamic stability to the vehicle during braking.

Two techniques are presented (with and without wheel slip) to satisfy both brake stability and performance while accommodating variations in load sharing and road friction coefficient. Based on parametric optimization of the design variables of hydraulic brake using evolutionary algorithm, taking into account both the laden and unladen circumstances simultaneously, this research develops an improved model for computing and simulating the BFD applied to commercial and passenger vehicles.

The optimal parameter values defining the braking system have been identified, resulting in effective β = 0.695 which enhances the brake forces at respective axles. Nominal slip of 3.42% is achieved with maximum deceleration of 5.72 m/s² maintaining directional stability during braking. The results obtained from both the methodologies are juxtaposed and assessed governing the vehicle stability in straight line motion to prevent wheel lock.

Optimization results establish the practicality, efficacy and applicability of the proposed approaches. The findings provide valuable insights for the design and optimization of hydraulic drum brake systems in modern automobiles, which can lead to safer and more efficient braking systems.