Industry 4.0

K. RajaramanDirector, Entrepreneurship Development Institute, Tamil Nadu

Www.editn.in

Industry 4.0Industry 4.0

Manufacturing : 5Ms

Materials Properties & Functions

Machines Precision & Capabilities

Methods Efficiency & Productivity

Measurements Sensing & Improvements

Modelling Prediction, Optimisation, Prevention

Industry 4.0

Industry 4.0

Definition

Industry 4.0 as the next phase in the digitization of the manufacturing sector, driven by four disruptions: the astonishing rise in data volumes, computational

power, and connectivity, especially new low-power wide-area networks;

the emergence of analytics and business-intelligence capabilities;

new forms of human-machine interaction such as touch interfaces and augmented-reality systems; and

improvements in transferring digital instructions to the physical world, such as advanced robotics and 3-D printing.

Developments across the World

● Smart Manufacturing Leadership Coalition ● Industrie 4.0 in the West● Made in China 2025 and ● Manufacturing Innovation 3.0 in the East● Share a common pursuit: Smart manufacturing.

Expected Outcomes

● Agility : Agile processes responsive to fluctuations or new trends in customer demands and customisation up to Batch size 1.

● Broaden the Innovation Base : Open architecture will stimulate entrepreneurs to develop manufacturing hardware and software that can be plugged into the SM platform for access by multiple users.

● Next-generation workforce : A manufacturing workforce with advanced skills and talent will be able to more fully take advantage of manufacturing intelligence.

● Promote Global Competitiveness : Pervasive application of data driven modeling and simulation, and to build continual improvements in manufacturing intelligence, performance, and competitiveness.

● Resource efficiency : Usable manufacturing intelligence on operational inputs (energy, water, materials, labor, and time) will allow factories to run more efficiently and minimize the use of precious resources.

Expected Outcomes - SMLC

● Demand-driven efficient use of resources and supplies in more highly optimized plants and supply

– 80% reduction in cost of modeling and simulation

– 25% reduction in safety incidents

– 25% improvement in energy efficiency

– 10% improvement in overall operating efficiency

– 40% reduction in cycle times

– 40% reduction in water

● Product safety

– Product tracking and traceability throughout the supply

● Sustainable production processes for current and future critical industries

– 10x improvement in time to market in target industries

– 25% reduction in consumer packaging

Definition

Digital-to-physical transfer.

Local Motors builds cars almost entirely through 3-D printing, with a design crowdsourced from an online community.

It can build a new model from scratch in a year, far less than the industry average of six.

Vauxhall and GM, among others, still bend a lot of metal, but also use 3-D printing and rapid prototyping to minimize their time to market.

Platforms

“Platforms,” in which products, services, and information can be exchanged via predefined streams. Think open-source software applied to the manufacturing context.

For example, a company might provide technology to connect multiple parties and coordinate their interactions. SLM Solutions, a 3-D-printer manufacturer, and Atos, an IT services company, are currently running a pilot project to develop such a marketplace.

Platforms: Manufacturing as a Service

‘Uber’isation of manufacturing: SMEs can perhaps setup their own cooperative cloud manufacturing platforms. It is known that SMEs could suffer from low capacity utilisation cycles. Manufacturing as a service could enable cooperative targeting of better capacity utilisation!

For eg, the manufacturers of printing machines have traditionally made the bulk of their revenues from selling and servicing presses. When the presses generate usage data, the manufacturers can become brokers of press time, knowing when customers’ presses are available, and negotiating printing prices accordingly.

Highly customised products

Customer can create her own perfume from millions of possibilities via a web portal.

Smart Factory can produce 36 000 Unique Perfume Packages per day

24 hours after the order via the Internet has been completed the individualized product is ready for shipment.

Since the customer of an individualized product, designed by herself, she does not accept long delivery times, the product should be produced close to the customer.

Adidas : SpeedfactoryProducing your own shoes The costumers can design their own short

shoes using an App. Since the customer wants to receive his personalized product on the next day or faster, long logistic chains from low-wage countriesare no longer acceptable in the era of mass customization.

Thus, Adidas decided to open various "Speed Factories" for personalized shoes in Germany close to the customer, using Cyber-physical production systems (CPPS).

Adidas : SpeedfactoryProducing your own shoes

Active Semantic Product Memory

Smart services based on active digital product memories

Pay-by-use

Pay-by-use and subscription-based services, turning machinery from capex to opex for manufacturers.

Rolls-Royce pioneered this approach in its jet-engine business; other manufacturers have followed suit.

Atlas Copco, a manufacturer of air compressors based in Nacka, Sweden, is moving away from selling its equipment directly, and, instead, is billing only for the compressed air that is used. The machines installed at customer sites can monitor the flow of compressed air and adjust the output according to customer need, who pay as they use.

Pay-by-use

Businesses that license intellectual property. Today, many manufacturing companies have deep expertise in their products and processes, but lack the expertise to generate value from their data. SAP offers consulting services that build on its software. Qualcomm makes more than half of its profits from intellectual-property royalties.

Manufacturers might offer consulting services or other businesses that monetize the value of their expertise.

Smart components:Autodiagnosis & configurabilityThe sensors integrated in the pump record key operating data that is then evaluated directly at the pump by PumpMeter. This information is used to automatically adapt operation to changing operating conditions and to optimise operation through PumpDrive. On-site displays or mobile terminals can be used to determine the operating point of the pump, identify optimisation potential and adapt and reconfigure operating modes. This information can also be accessed in vertical and horizontal integration setups via a large number of field buses used in conjunction with a cloud-based connection, for example.

KSB: Digital pumps

Internet of Things

Advanced analytics.

Stronger analysis can dramatically improve product development. One automaker uses data from its online configurator together with purchasing data to identify options that customers are willing to pay a premium for.

With this knowledge, the automaker reduced the options on one model to just 13,000—three orders of magnitude fewer than its competitor, which offered 27,000,000. Development time and production costs fell dramatically; most companies can improve gross margin by 30 percent within 24 months.

Advanced analytics. Analysis of your customers’ daily and seasonal use of

machinery can help improve production schedules. Data about employee performance can determine

training needs and scheduling Production data can illuminate opportunities to

eliminate downtime or speed up throughput. Analytics can also help meet aspirations that seemed

nearly impossible before. For example, many companies struggle to improve their eco-footprint.

Analytics can identify wasted materials and suggest ways to reclaim them, or to use them as inputs for other industrial processes.

TPM gets smarter → PHM (IMSI)

Smart logistics

It is possible to transmit digital information over large distances with low energy consumption using Bluetooth Low Energy (BLE). Many procedures in logistics are simplified and the efficiency of numerous processes is improved. With their small size, high data security and low cost, BLE tags are universally applicable and fulfil a wide range of requirements. The special sensors in the tags can produce an exact profile of the ambient conditions during the dispatch, transport and receipt of the goods to enable the status and incidents to be checked.

KSB: Digital pumps

Digital Compass of Options

With production data now available for the asking, executives rightly wonder about how to begin. Which data would be most beneficial? Which data leakages are causing the most pain? Which technologies would deliver the biggest return on investment for a company, given its unique circumstances?

To sort through the choices, manufacturing leaders can use a “digital compass”

Digital Compass of

Options for

Manufacturers

Preparing for the future

To get the most out of Industry 4.0 technologies, and to get past square one with a digital business model, companies will have to take a third step: prepare for a digital transformation.

Manufacturers should begin today to join the hunt for the best digital talent, and think about how to structure their digital organization.

Data management and cybersecurity will be critical problems to solve. Many companies will find that a “two speed” data architecture can help them deploy new technologies at the speed required, while also preserving mission-critical applications.

Emerging standards

Cyber security : cyber-diode

The risks of networking highly critical control systems can be minimised through the use of the “cyber-diode”. This solution monitors network connections and only allows one-way data transfer – information flow in the opposite direction is completely blocked. Systems protected in this manner are free to send control information via the Internet without becoming vulnerable to attack and risk their integrity being compromised.

The “cyber-diode” allows data transfer rates of up to 1 Gbit/s for TCP and UDP protocols and supports FTP file transfer and SMTP for e-mail traffic.

Implications of I4.0

These changes and many others like them are sure to be far reaching, affecting every corner of the factory and the supply chain.

The pace of change, however, will likely be slower than what we’ve seen in the consumer sector, where equipment is changed frequently.

Nearly 25% of industry leaders surveyed expected those improvements, in both cost savings and revenues, to exceed 20 percent over the next five years.

Thank you...