The digital convergence of manufacturing/production and associated sectors, as well as value generation processes, is known as Industry 4.0. The continuing modernization of conventional industries and business practices using new smart technologies is known as the Fourth Industrial Revolution (or Industry 4.0). The internet of things (IoT) and large-scale machine-to-machine communication (M2M) are being implemented for increased automation, better communication and self-monitoring, and the development of smart machines that can identify and diagnose problems without the need for human interaction.
A) Where all started
German Industrie 4.0 strategy
The word “Industrie 4.0,” abbreviated as I4.0 or simply I4, was coined in 2011 as part of the German government’s high-tech policy, which encourages the computerization of production. In the same year, at the Hannover Fair, the word “Industrie 4.0” was first used officially. In October 2012, the Working Group on Industry 4.0 presented the German federal government with a set of Industry 4.0 implementation recommendations.The hallmarks of the German government’s Industry 4.0 policy include extensive product customization under extremely scalable (mass-) manufacturing conditions.Introduction of self-optimization, self-configuration, self-diagnosis, cognition, and intellectual assistance of staff in their increasingly complex jobs improves the requisite automation technologies.
B) Design principles and goals
Interconnection:The Internet of Things, or the internet of humans, is the capacity of computers, software, sensors, and people to interact and communicate with one another (IoP).
Information transparency:Industry 4.0 technology’s openness offers operators with a wealth of data on which to base their decisions. Interconnectivity enables operators to capture massive volumes of data and information at all points of the production chain, as well as define key areas where flexibility can be improved.
Technical assistance: The ability of computers to assist humans in making decisions and solving problems, as well as the ability to assist humans with complex or dangerous tasks.
Decentralized decisions: The capacity of cyber physical devices to make independent decisions and execute activities as independently as possible. Tasks are only assigned to a higher rank in the event of exceptions, interruption, or opposing priorities.
C) Components
Many elements make up the Fourth Industrial Revolution, including:
*Mobile device
*Internet of things (IoT) platforms
*Location detection technologies (electronic identification)
*Advanced human-machine interfaces
*Authentication and fraud detection
*Smart sensors
*Big analytics and advanced processes
*Multilevel customer interaction and customer profiling
*Augmented reality/ wearables
*On-demand availability of computer system resources
*Data visualization and triggered “live” training
These innovations can be broken down into four main categories, which define the word “Industry 4.0” or “smart factory”:
*Cyber-physical systems
*Internet of things (IoT)
*On-demand availability of computer system resources
*Cognitive computing
To build value, Industry 4.0 connects a wide variety of emerging technologies. A simulated replica of the real world can be created using cyber-physical structures that track physical processes. The freedom to make decentralised decisions independently, achieving a high degree of control, is one of the characteristics of cyber-physical devices.
D) AREAS USED
The Imagination Age begins with the Fourth Industrial Revolution.
*Smart factory
The Fourth Industrial Revolution promotes the creation of a “smart factory.” Cyber-physical networks track physical operations, build a simulated replica of the physical environment, and make decentralised decisions within scalable hierarchical smart factories. Cyber-physical networks interact and collaborate in real time with each other and with humans through the internet of things, both centrally and through corporate resources delivered and used by value chain members.
*Predictive maintenance
Because of the use of technology and IoT instruments, Industry 4.0 will also provide predictive maintenance. Machine owners can do cost-effective repairs and assess it ahead of time before the equipment fails or is disabled through predictive maintenance, which can detect maintenance problems in real time.A business in LA, for example, would be able to tell whether a piece of equipment in Singapore is operating at an irregular pace or temperature. They’d be able to determine whether or not it needed to be fixed.
*3D printing
According to reports, 3D printing technology would play a significant role in the Fourth Industrial Revolution. 3D printing has many benefits for manufacturing, including the ability to print multiple geometric shapes and the ability to automate the product creation process. It’s still not that bad for the climate. It can also reduce lead times and overall production costs in low-volume processing. It will also help the company follow a mass customization business strategy by increasing flexibility, reducing warehousing costs, and assisting in the implementation of a mass customization business strategy. Furthermore, 3D printing can be very useful for printing replacement parts and assembling them locally, reducing reliance on suppliers and shortening delivery lead times.
*Smart sensors
Sensors and instrumentation are the driving forces behind Industry 4.0, as well as other “smart” megatrends like smart manufacturing, smart mobility, smart homes, smart towns, and smart factories.
Smart sensors are devices that produce data and allow additional functionality ranging from self-monitoring and self-configuration to complex process status monitoring. They help realise a dense variety of sensors by reducing construction effort and using wireless networking capabilities.
*Agriculture and Food Industries
In both of these areas, smart sensors are still in the testing stage. The information available in the plots is collected, interpreted, and communicated using these advanced linked sensors (leaf area, vegetation index, chlorophyll, hygrometry, temperature, water potential, radiation).The goal is to allow real-time tracking through a smartphone with a set of advice that optimises plot management in terms of performance, time, and costs based on this scientific evidence. These sensors may be used on the farm to monitor crop phases and suggest the appropriate inputs and treatments at the appropriate times. In addition, the degree of irrigation can be regulated.
E) BENEFITS
Productivity Gains
To put it another way, Industry 4.0 innovations enable you to do more for fewer. To put it another way, you can deliver better and quicker when allocating your money in a more cost-effective and productive manner.
Because of improved process control and automated/semi-automated decision-making, the manufacturing lines would have less downtime. In reality, as you get closer to being an Industry 4.0 Smart Factory, the overall OEE (Overall Equipment Effectiveness) will increase.
Improved Efficiency
As a result of Industry 4.0-related technology, several areas of the production line can become more effective. Any of these efficiencies have already been listed, such as reduced computer downtime and the potential to produce more goods at a faster rate.
Enhanced Knowledge Sharing and Collaborative Work
Industry 4.0 innovations allow the manufacturing lines, business processes, and teams to collaborate with one another regardless of location, time zone, network, or other factors. This allows information gained by a sensor on a computer in one factory, for example, to be disseminated within the company.
Agility and adaptability
Increased stability and mobility are also advantages in Industry 4.0. In a Smart Factory, for example, scaling up or down output is much easier. It’s much quicker to add additional products to the assembly line, as well as allowing for one-off manufacturing runs, high-mix manufacturing, and other possibilities.
Makes it Easier to Comply
In industries like pharmaceutical and medical device manufacturing, complying with regulations does not have to be a manual operation. Industry 4.0 innovations, on the other hand, make it easier to simplify regulatory processes such as monitor and trace, product inspections, serialisation, data recording, and more.
Improved Customer Service
Industry 4.0 also has ways to boost customer service and improve the user experience. You can easily fix issues with automatic track and trace capabilities, for example.Furthermore, you will have less stock supply challenges, product consistency will rise, and you will be able to provide consumers with more options (see the point about increased profitability below).
Reduces Costs
It takes time to become a Smart Factory, and it won’t happen on its own. You must pay to do that, because there are some upfront costs. However, as a result of Industry 4.0 innovations such as robotics, systems integration, data storage, and more, the cost of production at your plants will drop significantly.
Primary drivers for these reduced costs include:
-Better use of resources
-Faster manufacturing
-Less machine and production line downtime
-Fewer quality issues with products
-Less resource, material, and product waste
-Lower overall operating costs
-Creates Innovation Opportunities
Higher Revenues
Many of the points mentioned above will lead to increased sales for your production facility. For example, you might add a new change with low labour costs to accommodate an increase in demand or bid for a new contract by completely automating the manufacturing line and incorporating other Industry 4.0 technology.
Increased Profitability
Many of the points mentioned above would help you gain this Industry 4.0 advantage, including increased sales and lower costs.