INDUSTRY 4.0: APPLICATIONS IN MANUFACTURING.

Industry Evolution from 1.0 to 4.0

It's essential to understand how the manufacturing industry has evolved since the 1800s.
There have been four significant industrial revolutions in the history of the globe, one of
which is currently ongoing.

First Industrial Revolution

The first industrial revolution occurred between the late 1700s and the early 1800s. During
this time, industry progressed from relying on human labor supported by work animals to a
more efficient delivery system based on water and steam-powered engines and other
machine tools.

The Second Industrial Revolution

With the arrival of steel and electricity in industries in the early twentieth century, the
world underwent a second industrial revolution. Manufacturers were able to boost
productivity and make manufacturing machines more mobile after the arrival of electricity.
As a means of increasing productivity, mass production techniques like the assembly line
were implemented.

The Third Industrial Revolution (The digital Revolution)

The third industrial revolution began to develop in the late 1950s when manufacturers
incorporated more electrical and computer technology into their facilities. Manufacturers
started to move their focus away from analog and mechanical technologies and toward
digital technology and automation software during this time.

The Fourth Industrial Revolution (Industry 4.0)

Industry 4.0 brings digital technology from previous decades to a whole new level through
interconnection via the Internet of Things (IoT), access to real-time data, and the
introduction of cyber-physical systems. Industry 4.0 brings a more holistic, interconnected,
and complete approach to production. It helps to connect the actual and digital worlds,
allowing for improved cooperation and access across departments, partners, vendors,
products, and people. Industry 4.0 enables business leaders to oversee better and understand
every part of their operations and use real-time data to increase efficiency, streamline
procedures, and accelerate growth.

Figure: Industrial Revolution Timeline

What is industry 4.0?

"Industry 4.0" refers to the start of the fourth industrial revolution, which follows mechanical
manufacturing, mass production, and finally, the digital revolution. It's claimed that Industry
4.0 is just a mash-up of the three preceding industrial periods, but Industry 4.0 is set to be far
more significant.

Head of the World Economic Forum Klaus Schwab summarized the recently named Industry
4.0:

Industry 4.0 is the fusion of these technologies [AI, big data, IoT, bioinformatics] and their
interaction across the physical, digital, and biological domains that distinguishes the Fourth
Industrial Revolution from previous revolutions by disseminating faster and further than any
previous revolution.
Industry 4.0 Technologies

Because of the extensive use of digital technology in formerly manual operations, Industry
4.0 has made the smart factory a reality. The digital transformation of Industry 4.0 is driven
by connectivity, automation, and optimization. However, several technologies are
collaborating to fulfill the manufacturing 4.0 movement's potential fully.

1. Industrial Internet of Things (IIoT)

The Industrial Internet of Things (IIoT) refers to the interconnection and
cooperation of data, machines, and people in the industrial industry. It takes the
Internet of Things (IoT) — sensors, devices, and data all connected and seamlessly
interacting – and applies it to production. In the IIoT, every part of the industrial
process may be combined, and the data generated can be used to improve efficiency
across the operation.
2. Automation
The ultimate purpose of a connected factory is to increase efficiency and thereby
revenues. Automation must be implemented in some or all production processes to
achieve this. The interconnectedness and communication that happens across an
Industry 4.0 optimized facility enable automation via robots or AI.
3. Artificial Intelligence
For an Industry 4.0-enabled smart factory, artificial intelligence and its subset of
machine learning are a need. The entire idea of this new industrial revolution is to
eliminate manual processing, with AI serving as the vital instrument to do it. AI may
leverage data from a connected factory to optimize machines, reprogram operations,
and discover general changes that can be done to increase efficiency and income.
4. Big Data & Analytics
There is a lot of data to sort through because every function of the manufacturing
operation is monitored and generates data. On the other hand, big data analytics
solutions may use machine learning and AI to swiftly analyze data and provide
decision-makers with the knowledge they need to optimize a manufacturing
operation as a whole.

5. The Cloud
Manufacturers don't have or want to utilize the large amount of space necessary to
physically store vast amounts of data collected in an Industry 4.0 operation. This is
 why cloud storage and computing are a must-have component of connected
production. Cloud computing also enables a single source of truth and rapid data
exchange across the organization. Finally, cloud storage allows remote access and
monitoring of all data and machine operating systems, increasing visibility and
efficiency.
6. Cybersecurity
Because Industry 4.0 connects and digitizes every touchpoint in the production
process, it needs even more sophisticated cybersecurity. Manufacturing equipment,
computer systems, data analytics, the cloud, and any other IoT-connected system
should be safeguarded.
7. Simulations
The significant game-changers in the age of Industry 4.0 and manufacturing is the
capacity to foresee consequences. Changing a product line and improving its speed
and production before the factory's digitalization was a bit of guessing and always
imprecise. Manufacturing operations may optimize machinery for their following
product run using today's sophisticated simulation models backed by IoT data and
AI, saving time and money.

Figure: Smart Manufacturing.

Smart Manufacturing

Consider how intelligent manufacturing may be used for your firm or a business
comparable to yours to have a deeper understanding of the idea. Here are some examples of
how Industry 4.0 might benefit a manufacturing operation:

1. Digital performance management

The consulting company recommends digital performance management because it is a
crucial first step in establishing Industry 4.0 skills and infrastructure. To interpret
continuous, real-time data from people and equipment, digital performance
management applications rely on Industrial Internet of Things connection and cloud
storage. Operators may evaluate and respond to process performance in real-time
using digital dashboards and manufacturing applications. Engineers may adjust KPIs
to their operations using flexible performance management tools. Constant data
interaction fosters an evidence-based mindset, a vital first step toward a more
analytical process.
2. Predictive Maintenance
Predictive maintenance has improved as MES, manufacturing software, and
analytical systems have evolved. Predictive maintenance systems are becoming
more sensitive by the day, thanks to breakthroughs in big data, human performance
tracking, and machine learning. Deep-learning algorithms can develop maintenance
plans that get more accurate over time for factories with a primary degree of
connection. As AI zeroes in on inefficiencies, they've already resulted in significant
increases in OEE and significant reductions in machine downtime. As computer
vision and wearable sensors transform human actions into usable data, more
advancements in this field will be made.
3. Process optimization
Industry 4.0 aims to collect data from machines and evaluate it using advanced
algorithms. This, however, does not have to be confined to single processes or lines.
On the other hand, early adopters are experiencing significant benefits when they
leverage their data to establish systems inside departments, then combine those
 systems into a responsive, fully connected whole. Optimizing the whole value chain
will yield some of the most significant Industry 4.0 benefits.

4. Advanced automation
According to most top research organizations, robotics usage in manufacturing is
expected to grow in the next ten years. However, robotics is only one aspect of
automation. Many knowledge occupations will also face automation, according to
McKinsey, as algorithms become more competent in managing demand, scheduling
inventories, and undertaking root-cause analysis.

Figure: IIOT and its Impact

Smart manufacturing in Automotive Industry

The automotive industry is made up of a diverse group of businesses and
organisations that are involved in the design, development, production, marketing,
and sale of automobiles. Original equipment manufacturers (OEMs), suppliers,
dealers, captive finance organisations, and others working in the mobility ecosystem
have all benefited from Industry 4.0, which has expanded the possibilities of digital
transformation in the automotive industry while also emphasizing its
importance.Using Co-bots with smart manufacturing is the era where industry 4.0 has
entered into automotive industry. Co-bots are collaboration robots designed to engage
directly with humans within a location. For more than 50 years, the automobile
industry has used robots in its assembly lines for a variety of industrial tasks.
Automobile makers are currently investigating the use of robots in a wider range of
processes. Robots are more efficient, precise, versatile, and trustworthy on these
manufacturing lines. Thanks to this technology, the automobile sector has remained
one of the most automated supply chains in the world, as well as one of the major
users of robots. Companies across the value chain are becoming more flexible,
efficient, and responsive by leveraging the power of combined and connected digital
and physical technologies—artificial intelligence, the Internet of Things, additive
manufacturing, robotics, cloud computing, and others—and reshaping how they
operate their businesses, engage customers, and deliver products and services.

Robotics in the Automotive Industry:

Every automobile and truck contains thousands of pieces, which are made using a
variety of manufacturing procedures. Because of advancements in automotive
robotics technology, such as vision systems and force sensors, more vehicles are now
suitable for robotic automation than ever before.

Some of the best-suited application areas are as follows:

Welding (SPOT AND ARC): Large robots with a large payload and extended reach
can spot weld automobile body panels, while smaller robots weld subassemblies like
brackets and mounts. Every cycle, robotic MIG and TIG arc welding places the flame
in the same direction, and repeatable speed and arc gap ensure that every fabrication
meets the same high quality.

Assembly: In vehicle production factories, tasks like screw driving, windshield

installation, and wheel mounting are all potential for robotic arms. Robots assemble
 smaller component assemblies such as pumps and motors in various automobile part
facilities, such as the high-speed "Delta" machines.

Machine Tending: Robots tending manufacturing machines include unloading hot

mouldings from an injection moulding or die casting machine, as well as loading and
unloading CNC machining centres.

Material Removal: A robot is perfect for light trimming and cutting chores since it
can follow a complicated path repeatedly. Cutting textiles for headliners, reducing
flash from plastic mouldings and die castings, and polishing moulds are just a few
examples. In applications like these, force-sensing technology allows the robot to
maintain consistent pressure against a surface.

PART TRANSFER: Pouring molten metal in a foundry and moving a metal stamp
from one press to another are both unpleasant activities for humans, but they're great
robot duties.

In the automotive industry, machine learning (ML) is most often associated with
product innovations, such as self-driving cars, parking and lane-change assists, and
smart energy systems.

Industry 4.0 Outcomes

Most significant benefits manufacturers can expect from Industry 4.0:

1. Optimized Processes

All of Industry 4.0's connections — sensors, IoT, AI, and so on – serve a single
goal: to improve industrial processes. Automation allows factories to work more
quickly, while data analytics enables executives to make data-driven choices to
boost efficiency. Predictive maintenance reduces machine downtime, and
monitoring systems give real-time yield optimization across the operation. It leads
to more income and better customer service in the case of Industry 4.0 and digital
transformation when manufacturers can get the most out of their production using
sensor-monitored machinery while providing individualized attention and quick
service to their consumers.

2. Greater Asset Utilization

 Industry 4.0 enables more flexibility across the industrial operation, resulting in
higher asset utilization and, as a result, the possibility for increased income.
Consider automation: autonomous mobile robots (AMR) can do low-value jobs like
product delivery, freeing up experienced human employees to focus on higher-value
duties.

3. Higher Labor Productivity

Employees can focus better and complete more work when they feel more
comfortable on the job. The significant advantage of IoT solutions on the production
floor is worker safety: sensors installed on-site and worn by workers are continually
monitored to ensure a safe and healthy working environment. Many factory workers'
skill sets are being expanded as a result of Industry 4.0. Workers are acquiring new
abilities to boost operational efficiency and skill set when new technology is
introduced into the operation. Consider cobots (collaborative robotics): humans and
robots collaborating in industrial operations to increase efficiency and profits.

4. Supply Chain and Inventory

Manufacturers may gain insight into the whole supply chain and production process
with IoT-enabled sensors and data analytics. This amount of insight, paired with AI
and machine learning capabilities, allows for real-time supply chain improvement.
Some define Supply Chain 4.0 as "the application of the Internet of Things, the use
of advanced robotics, and the application of advanced analytics of big data in supply
chain management: place sensors in everything, create networks everywhere,
automate anything, and analyse everything to improve performance and customer
satisfaction significantly: place sensors in everything, create networks everywhere,
automate anything, and analyse everything to improve perfomance and customer
satisfaction significantly: place sensors in everything, create networks everywhere,
automate anything, and analyse everything to improve perfomance.

5. After-Sales Services

After manufacturing, Industry 4.0's foundations, such as predictive analytics,

virtual reality, and remote monitoring, make their way to the consumer market.
 Designing goods that can connect to the internet of things might dramatically
expand customer and field service options. Customer service is a competitive
differentiator for firms, and connected field service equipment is helping to improve
customer satisfaction. Manufacturers may use linked devices to monitor product
performance, plan maintenance before an issue arises, and reduce customer
dissatisfaction.

Figure: Industry 4.0 Outcomes

Challenges of Using Industry 4.0:

1. Cyber Security Issues:

Cyber security risks may arise as a result of the deployment of IoT and cloud-based
technologies. Cyber-attacks on a company's servers and databases, on the other hand,
may result in concerns such as data loss and manipulation. Furthermore, cyber-attacks
on the organization's systems might leak private information about the company.

2. Technical Issues:

Industry 4.0 is a system that combines intelligent cyber-physical machinery, cloud-

based databases, information-sharing IoT technologies, and mixed reality
technologies. Technical difficulties might arise as a result of improper technology
maintenance or inefficient machine handling. Due to technological challenges,
manufacturing organization managers may find it difficult to adopt any changes to the
manufacturing system or supply chain.

3. Challenges Related to Employee Training:

Following Industry 4.0, it is critical for manufacturing companies to properly teach
their personnel how to use digital technology and intelligent devices in production.
They will be unable to manage those technologies adequately without sufficient
training, resulting in technical complications.