Unit 10

Future of Automated Factory

 Industry 4.0

4th Industrial Revolution – Industry 4.0

1st Revolution : Mechanization, Water and Steam Power

2nd Revolution: Mass Production, Assembly Line, Electricity

3rd Revolution: Computer and Automation

4th Revolution: ?? Cyber Physical Systems

Industry 4.0: Name for the current trend of Automation and Data
exchange in Manufacturing Sector
Industrial Revolutions
Industrial Revolutions
Industry 4.0 – Concept of SMART FACTORY

Cyber Physical systems monitor physical processes in a factory floor

De-centralized decision making systems

For a factory to be considered as Industry 4.0 standards:

• Interoperability — machines, devices, sensors and people that connect and

communicate with one another.

• Information transparency — the systems create a virtual copy of the physical world
through sensor data in order to contextualize information.

• Technical assistance — both the ability of the systems to support humans in making
decisions and solving problems and the ability to assist humans with tasks that are too
difficult or unsafe for humans.

• Decentralized decision-making — the ability of cyber-physical systems to make

simple decisions on their own and become as autonomous as possible
 Industry 4.0 – Who started it and When?

German Government coined the word Industrie 4.0 in 2013 in an internal

government memo

Chancellor Angela Merkel introduced the concept in the World Economic Forum in
2015

German Government invested €200 Million

US followed with Smart Manufacturing Leadership Coalition (SMLC)

Industry 4.0 : Goals are to define a vision for the factory of the future in 2030
Industry 4.0 – What is driving it?
Industry 4.0 – 9 Technologies transforming Industrial Production
Industry 4.0 – 9 Technologies transforming Industrial Production

Big Data Analytics

Collection and comprehensive evaluation of data from many different sources—
production equipment and systems as well as enterprise- and customer-management
systems—will become standard to support real-time decision making.

Autonomous Robots
Robots will eventually interact with one another and work safely side by side with humans
and learn from them. These robots will cost less and have a greater range of capabilities
than those used in manufacturing today.

Simulation
Mirror the physical world in a virtual model, which can include machines, products, and
humans. Allow to test and optimize the machine settings for the next product in line in the
virtual world before the physical changeover.

Horizontal and Vertical System Integration

Companies, departments, functions, and capabilities will become much more cohesive, as
cross-company, universal data-integration networks evolve and enable truly automated
value chains.
Industry 4.0 – 9 Technologies transforming Industrial Production
Industrial IoT
Field devices to communicate and interact both with one another and with more centralized
controllers, as necessary. It will also decentralize analytics and decision making, enabling real-
time responses.

Cyber Security
The need to protect critical industrial systems and manufacturing lines
from cybersecurity threats. Secure, reliable communications as well as sophisticated identity
and access management of machines and users.

Cloud
Increased data sharing across sites and company boundaries. Performance of cloud
technologies will improve, achieving reaction times of just several milliseconds. Data-driven
services for production systems.

Augmented Reality
Support a variety of services, such as selecting parts in a warehouse and sending repair
instructions over mobile devices. The technology is currently in its infancy

Additive Manufacturing
 Industry 4.0

Enabled by technologies that integrate the digital and real worlds, such as:

• The Internet of Things (IoT): Connecting more and more systems, devices, sensors, assets and
people through networks ranging from wireless, low-power wide-area networks to wired high-
capacity networks

• Mobile solutions: Including smart phones, tablets, wearable sensors and smart glasses

• Cloud computing: Including low-cost processing and data storage solutions

• Cyber-physical systems (CPS): Monitoring and controlling physical processes using sensors,
actuators and processors, based on digital models of the physical world

• Big data analytics and business intelligence: Turning data into actionable insights, which
include early warning algorithms, predictive models, decision support, workflows and dashboards

• Advanced manufacturing technologies: Including robotics and 3D printing

 Industry 4.0 - Benefits

Staying Connected
Real Time Connected supply chain

Accommodate Critical orders

Connected Vehicles, Containers, Pallets. Control condition and location of product in the entire
supply chain.

Improve inventory management. Deal with counterfeit products.

Smart production. Monitor and control remotely. Improved worker safety.

Energy management and Predictive Maintenance.

 Industry 4.0 – Challenges in Implementing

Manufacturers deal with huge quantities of information, both structured and unstructured, which
reside in databases that are not always properly connected

• Awareness: About its existence and benefits

• People: Transformation in the way employees work everyday. Require people with different &
new skill set

• Cyber security: Traditional IT security may not be enough to protect businesses. Must be able to
integrate into existing automation systems.

• Investments: Need to be justified.

• Collaboration: No single vendor can deliver all the requirements to implement Industry 4.0
solutions.

• Standardization: Current standards not enough to fulfill Industry 4.0 implementation. No

universal standard for Industry 4.0

• IT Modernization: Connecting businesses, technology, logistics, hardware etc.

Industry 4.0 – Challenges in Implementing
 Industry 4.0 – Smart Factory

Factory of the FUTURE

Enhance production by making improvements in three dimensions

• Plant structure

• Plant digitization

• Plant processes
 Industry 4.0 – Smart Factory
Factory of the FUTURE

Plant structure

• Flexible and Multidirectional layout

• Modular line setup

• Environmentally sustainable process

Plant Digitization

• Installing smart and autonomous robots

• Use collaborative robots (with humans without worrying about security)

• Additive Manufacturing

• Use of augmented reality and simulations

• Use of big data analytics

 Industry 4.0 – Smart Factory
Factory of the FUTURE
Plant Processes

• Customer centric (last minute modifications, customization in mass production)

• Continuous improvement
 IoT – Internet of Things

The internet of things (IoT) is a computing concept that describes the idea of everyday
physical objects being connected to the internet and being able to identify themselves to other
devices and communicate with them.

A network comprised of physical objects capable of gathering and sharing electronic

information

Connecting any device with an on and off switch to the Internet (and/or to each other). This
includes everything from cell phones, coffee makers, washing machines, headphones, lamps,
wearable devices and almost anything else you can think of.

This also applies to components of machines, for example a jet engine of an airplane or the
drill of an oil rig.
 IoT – Internet of Things
The new rule for the future: "Anything that can be connected, will be connected.“

What does this mean? How does it impact everyday life?

Limitless opportunities

Big Challenges in implementation

SECURITY????

Massive amount of data – Technologies to STORE and PROCESS, make sense of it

Consumer Applications, Smart Homes, Assistive devices for disabled , Media networks,

Infrastructure Management, Manufacturing, Agriculture, Energy and Environment

management, Medical and Healthcare, Transportation

 IoT – For Manufacturing

An entirely connected factory

Systems collaborating and communicating with each other

Flexibility

USES?

Key component to implement Industry 4.0

Predictive Maintenance Manufacturing Operations

Process Optimization Quality improvement using data

(production to customer review)
Remote Monitoring

Vendor Management

Supply Chain Optimization