Industry 4.0

Presentation of
Smart manufacturing
On
Industry 4.0
By,
Nawal Sinha
MT/EE/10024/19

CONTENTS
 Introduction
 Origin of industry 4.0
 Characteristics
 Smart factory
 Tempo automation
 Advantages of industry 4.0
 Conclusion
 References

INTRODUCTION
 Industry 4.0 enables the manufacturing sector to become
digitalized with built-in sensing devices virtually in all
manufacturing components, products and equipment.
 The analyzing of related data within a ubiquitous system with
the fusion of digital data and physical objects has the ability to
transform every industrial sector in the world to evolve much
faster and with greater impact than any of the three previous
industrial revolutions
 Under Industry 4.0, production will become more efficient and
less costly.
 This is achieved by easy exchange of information and the
integrated control of manufacturing products and machines
acting simultaneously and smartly.

 The first industrial revolution:
It began with the mechanization and mechanical power
generation in 1800s. It brought the transition from manual work to
the first manufacturing processes; mostly in textile industry.
 The second industrial revolution:
It was triggered by electrification that enabled industrialization
and mass production. It was the introduction of mass production
but without the possibility of products customization.
 The third industrial revolution:
It is characterized by the digitalization with introduction of
microelectronics and automation. In manufacturing this facilitates
flexible production, where a variety of products is manufactured
on flexible production lines with programmable machines. Such
production systems however still do not have flexibility
concerning production quantity.

Origin of Industry 4.0
 The basic concept was first presented at the Hannover fair, Germany in
the year 2011.
 The main idea was to exploit the potentials of new technologies and
concepts such as:
• availability and use of the internet and IoT,
• integration of technical processes and business processes in the
companies,
• digital mapping and virtualization of the real world,
• ‘Smart’ factory including ‘smart’ means of industrial production
and ‘smart’ products.
 According to some sources, Industry 4.0 factory could result in
decrease of: • production costs by 10-30%,
• logistic costs by 10-30%,
• quality management costs by 10-20%.

Fig 1: Revolution of industries

Characteristics Of IIoT
 Cyber-Physical System (CPS) :
Industry 4.0 can be played as a Cyber-Physical System study where the
advances and speed of development in communication and calculation form
the Cyber-Physical System and Industry 4.0. Each production system of CPS
has sensors installed in the entire physical aspects in order to connect the
physical things with virtual models.
 Internet of Things (IoT) :
IoT can provide advanced connectivity of systems, services, physical objects,
enables object-to-object communication and data sharing. IoT can be achieved
through the control and automation of aspects like heating, lighting, machining
and remote monitoring in various industries.
 Internet of Services (IoS):
Activities are triggered through data transfers in the information technology to
make daily mobility safer, easier and pleasant. The IoS acts as “service
vendors” to provide services through the internet according to the types of
digitalization services. These services are available and on demand around
business models, partners and any setup for services.

 Big Data and Analytics:
Under Industry 4.0, it leads to huge amounts of information produced and
obtained daily where current processing and analysis is unable to cope using
traditional methods. Hence, big data has become a hot topic recently. Big
data is the utilization of digital technology to conduct analysis. According to
Forrester’s definition, “Big Data” can be divided into four dimensions which
are volume, variety, value and velocity.
 Augmented Reality(AR):
AR technology can bring huge support for maintenance works in business
due to reduced time needed for maintenance works and reduction of potential
errors in maintenance works. It can predict with high accuracy and allows
the frequency of maintenance to be kept at low numbers by utilizing
predictive maintenance to prevent any unplanned reactive maintenance. This
will reduce costs associated with doing too much preventive maintenance.
 Autonomous Robots:
Current robots have higher flexibility, advanced functions and are easier to
operate in multitudes of fields. In future, robots will interact with each other
and collaborate actively with humans under the guidance of handlers. These
robots will be cheaper and more sophisticated in order to achieve better
abilities compared to those currently used in the manufacturing field.

 Additive Manufacturing (3D Printing):
Industry 4.0 is stimulating the utilization of advanced data technologies and smart
production systems. Hence, additive manufacturing is one of the crucial tools to
embrace Industry 4.0. The implementation of new manufacturing skills for the
purpose of integrating information technologies plays a crucial role in the
competitiveness of the economy. The trend of looking for new materials available
using additive manufacturing is increasing.
 Cloud Computing (CM) :
Cloud computing is a relatively new system logic that provides a huge space of
storage for the user. Over time, the performance of technologies keep on
improving, however, the functionality of machine data will continue to be stored
into the cloud storage system, allowing production systems to be more data-driven.
Company limitations can be minimized since more data sharing will occur across
sites for production-related undertakings in the industrial revolution.
 Simulation:
It is a way of running a real or virtual process or a system to find out or guess the
output of the modeled system or process. Simulations are done by using real-time
data to represent the real world in a simulation model, which include humans,
products and machines. Therefore, operators are able to optimize the machine
settings in a virtual simulated situation before implementing in the physical world.
This decreases machine setup times and improves quality.

Fig 2: 9 pillars of industry 4.0

Smart factory
 A smart factory is a highly digitized and connected production
facility that relies on smart manufacturing.
 Thought to be the so-called factory of the future and still in its
infancy, the concept of the smart factory is considered an
important outcome of the fourth industrial revolution, or
Industry 4.0.
 The machinery and equipment are able to improve processes
through automation and self-optimization.
 The benefits also extend beyond just the physical production of
goods and into functions like planning, supply chain logistics,
and even product development.
 The technical foundations on which the Smart Factory - is based
on are cyber-physical systems that communicate with each other
using the Internet of Things and Services.

Fig 3 : Smart factory
 From the figure we can see that it is a smart factory, which works on
smart manufacturing and industry 4.0 technology. All the robots are
working and all the process like customer service, blockchain of
things, production, designs are being handles in an automation way.

TEMPO Automation
 Tempo Automation is the world’s fastest electronics manufacturer
for prototyping and low volume production of PCB assemblies.
 It has a 42,000-square-foot smart factory office in San Francisco’s
trendy Design District.
 The company’s facility, which uses IIoT to automatically configure,
operate, and monitor the prototyping and low-volume production of
printed circuit board assemblies (PCBAs).
 Tempo factory isn’t all fancy, the plant also includes an array of IoT
sensors that track :
 temperature,
 humidity,
 equipment status,
 job progress,
 reported defects,
 to help engineers understand how the facility is operating.

How does it works ?
 Tempo’s customers upload CAD files with their board designs
and Bills of Materials (BOM) listing the required parts to be used.
 After performing feature extraction on the design and developing
a virtual model of the finished product, the Tempo system, the
platform (called Tempocom) creates a manufacturing plan and
automatically programs the factory’s machines.
 Tempocom also creates work plans for the factory employees,
uploading them to the networked IIoT mobile devices they all
carry.
 Updated in real time based on design and process changes, this
“digital traveler” tells workers where to go and what to work on
next.
 While Tempocom is planning and organizing the internal work of
production, the system is also connected to supplier databases,
seeking and ordering the parts that will be used in assembly,
optimizing for speed of delivery to the Tempo factory.

Connecting the Digital Threads
 Tempo Automation uses Amazon web services (AWS) Gov
Cloud to network everything in a bi-directional feedback
loop.
 After customers upload their design to the Tempo platform,
the software extracts the design features and then streams
relevant data down to all the devices, processes, and robots
on the factory floor.
 This loop then works the other way: As the robots build the
products, they collect data and feedback about the design
during production.
 This data is then streamed back through the Tempo secure
cloud architecture to the customer as a ‘Production
Forensics’ report.”

Fig 4 : TEMPO Automation factory floor
 TEMPO contains 50 people and 50 robots, making it a connected
factory.

Advantages of industry 4.0
 There are number of advantages and reasons for the adoption of
this concept including:
 A shorter time-to-market for the new products.
 An improved customer responsiveness.
 Enabling a custom mass production without increasing overall
production costs.
 More flexible and friendlier working environment.
 More efficient use of natural resources and energy.
 Production costs were lowered with introduction of just-in-time
production.

Conclusion
 Industry 4.0 is the current vision shaping the future of many
industries by creating new business models through CPS.
 Therefore, it is crucial to investigate its dimensions in order
to realize efficiencies in the business environment.
 the concepts of Industry 4.0 are shortly described as well as
how they would help companies achieve their objectives
concerning Industry 4.0.
 The nine pillars (big data, autonomous robots, simulation,
additive manufacturing, IoT, cloud computing, augmented
reality, horizontal and vertical integration and cyber security)
of Industry 4.0 are defined as referring the findings of BCG
over Industry 4.0
 We have all seen some examples of how they are used in the
real life which gives the insights for future works conducted
on Industry 4.0 and future business models of the companies.

References
[1] Aiman, M. et al. 2016. Industry 4.0 : A review on industrial automation and robotic.
Jurnal Teknologi (Sciences & Engineering), 78, pp. 137-143.
[2] Akhtar, P. et al., 2017. The Internet of Things, dynamic data and information
processing capabilities, and operational agility. Technological Forecasting and
Social Change. Available at:
http://linkinghub.elsevier.com/retrieve/pii/S0040162517305504 [Accessed May 16,
2017].
[3]Presentation at the French Embassy in the Germany, “Industry of the future“, 2015.
Available at. http://www.ambafrance-de.org/Vorstellung-des-neuen-franzosischen-
PlansIndustrie-du-Futur-in-der-Botschaft. Last accessed: 24.11.2016.
[4] Kagermann, H., Wahlster. W . and Johannes, H. Recommendations for
Implementing the Strategic Initiative INDUSTRIE 4.0. Forschungsunion, 2013.
[5]Hermann, M. et al. 2016, Design Principles for Industrie 4.0 Scenarios: A Literature
Review. Available at
https://www.computer.org/csdl/proceedings/hicss/2016/5670/00/5670d928.pdf
[Accessed July 27, 2017].
[6] Hofmann, E. & Rüsch, M., 2017. Industry 4.0 and the current status as well as future
prospects on logistics. Computers in Industry, 89,
 https://www.etmm-online.com/what-is-smart-factory-definition-examples-industry-
40-technologies-a-825861/
 https://www.networkworld.com/article/3384378/an-inside-look-at-tempo-
automations-iiot-powered-smart-factory.html

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