industry 4.0

1. INDUSTRY 4.0
NGDT-II

2. CONTENTS
• Introduction
• Evolution of Industry 4.0
• Industry 4.0 – Enabling Technologies
• Design Principles & Building Blocks
• Industry 4.0- Examples

3. INTRODUCTION
• Industry 4.0 represents the current trend of automation technologies in the
manufacturing industry
• Includes enabling technologies such as the cyber physical systems (CPS),
Internet of Things (IoT) & cloud computing
• Represents the technological evolution from embedded systems to cyber-
physical systems
• Need of industry 4.0 is to convert the regular machines to self-aware & self-
learning machines to improve their overall performance & maintenance
management with the surrounding interaction

4. EVOLUTION OF INDUSTRY 4.0 (CONT’D)
FOUR INDUSTRIAL REVOLUTIONS

6. INDUSTRY 4.0: ENABLING TECHNOLOGIES
– “IoT”
• When IoT emerged, it was referred to uniquely identifiable
interoperable connected objects using radio-frequency identification
(RFID) technology
• Connecting RFID reader to the Internet, the readers can automatically
& uniquely identify & track the objects attached with tags in real-time
• Later on, the IoT technology was used with other technologies, such
as sensors, actuators, the Global Positioning System (GPS) & mobile
devices that are operated via Wi-Fi, Bluetooth, cellular networks or
near field communication (NFC)

7. INDUSTRY 4.0: ENABLING TECHNOLOGIES
– “IoT”
• IoT is:
• a dynamic global network infrastructure with self-configuring capabilities based
on standard and interoperable communication protocols where physical and
virtual ‘Things’ have identities, physical attributes, and virtual personalities and
use intelligent interfaces, and are seamlessly integrated into the information
network.

8. INDUSTRY 4.0: ENABLING TECHNOLOGIES
– “IoT”
IoT related technologies made a significant impact on new ICT and paved the
way for the realization of Industry 4.0

9. INDUSTRY 4.0: ENABLING TECHNOLOGIES
– “CLOUD COMPUTING”
• Computing technology which offers high performance at low cost
• Virtualization technology provides cloud computing with resource
sharing, dynamic allocation, flexible extension & numerous other
advantages
• Large volume of data can be uploaded to a cloud computing center for
storage & computation, which facilitates manufacturing & production
• Cloud-based manufacturing is a rising technology which can
contribute significantly to the realization of Industry 4.0 that enables
modularization & service-orientation in the context of manufacturing

10. INDUSTRY 4.0: ENABLING TECHNOLOGIES
– “CLOUD COMPUTING”
• Manufacturing enterprises require multiple computing resources such
as servers for databases & decision-making units
• Cloud computing provides an effective solution to such problems
• All data can be stored in private or public cloud servers.
• In this way, complex decision-making tasks can be supported by cloud
computing

11. INDUSTRY 4.0: ENABLING TECHNOLOGIES
– “CYBER PHYSICAL SYSTEMS (CPS)”
• CPS is the core foundation of Industry 4.0
• With the increased connectivity & use of standard communications
protocols that come with Industry 4.0, the need to protect critical
industrial systems & manufacturing lines from cyber security threats
increases dramatically
• The term CPS has been defined as the systems in which natural &
human made systems (physical space) are tightly integrated with
computation, communication and control systems (cyber space)

12. INDUSTRY 4.0: ENABLING TECHNOLOGIES
– “CYBER PHYSICAL SYSTEMS (CPS)”
• CPSs comprise smart machines, storage systems and production facilities
capable of autonomously exchanging information, triggering actions and
controlling each other independently
• CPS facilitates fundamental improvements to the industrial processes
involved in manufacturing, engineering, material usage and supply chain
and life cycle management
• Advances in CPS will enable capability, adaptability, scalability, resiliency,
safety, security & usability that will far exceed the simple embedded systems
of today

13. EXAMPLE: AUTOMOTIVE TELEMATICS
• In 2005, 30 – 90 processors per car
Engine control, Break system, Airbag deployment system
Windshield wiper, Door locks, Entertainment system
• Cars are sensors and actuators in V2V networks
Active networked safety alerts
Autonomous navigation
• Future Transportation Systems
Incorporate both single person and mass transportation vehicles, air and ground transportations.
Achieve efficiency, safety, stability using real-time control and optimization.

14. EXAMPLE: HEALTH CARE AND
MEDICINE
• National Health Information Network,
Electronic Patient Record
• Home care: monitoring and control
Pulse oximeters, blood glucose monitors, infusion
pumps, accelerometers, …
• Operating Room of the Future
Closed loop monitoring and control; multiple treatment
stations, plug and play devices; robotic microsurgery
System coordination challenge
• Progress in bioinformatics: gene, protein
expression, systems biology, disease
dynamics, control mechanisms

15. EXAMPLE: ELECTRIC POWER GRID
• Current picture:
Equipment protection devices trip locally, reactively
Cascading failure
• Better future?
Real-time cooperative control of protection devices
Self-healing, aggregate islands of stable bulk power
Coordinate distributed and dynamically interacting partcipants
Issue: standard operational control concerns exhibit wide-area characteristics
(bulk power stability and quality, flow control, fault isolation)

16. INDUSTRY 4.0: ENABLING TECHNOLOGIES
– “CYBER PHYSICAL SYSTEMS (CPS)”
Cyber Physical
System

18. DESIGN PRINCIPLES OF INDUSTRY 4.0
• INTEROPERABILITY
• The ability of machines, devices, sensors, and people to connect and
communicate with each other via the Internet of Things (IoT) or the Internet of
People (IoP)
• INFORMATION TRANSPARENCY
• The transparency afforded by Industry 4.0 technology provides operators with
vast amounts of useful information needed to make appropriate decisions

19. DESIGN PRINCIPLES OF INDUSTRY 4.0
• TECHNICAL ASSISTANCE
• Concerns the ability of the systems to support humans through comprehensive
aggregation & visualization of information for better decision-making and quick
solutions to problems
• Focuses on the ability of cyber-enabled systems to physically support human
resources by handling various tasks, which are considered time-consuming,
harmful & exhausting to people

20. DESIGN PRINCIPLES OF INDUSTRY 4.0
• DECENTRALIZED DECISIONS
• Refers to the ability of cyber-enabled systems to independently come up with
decisions and carry out their dedicated functions
• Only in the case of exceptions, interferences or conflicting goals, the tasks are
delegated to a higher level
• REAL-TIME CAPABILITY
• Industry 4.0 efforts are centered towards making everything real-time: the
gathering or collecting of data in each step of the process & even the feedback
and monitoring stage

21. DESIGN PRINCIPLES OF INDUSTRY 4.0
• MODULARITY
• Flexibility is also another design principle of Industry 4.0, so that Smart
Factories can easily adapt to changing circumstances & requirements
• The individual models must be designed in such a way that they can be
replaced, expanded, or improved on

23. BUILDING BLOCKS

24. BUILDING BLOCKS
• 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
• Simulations will be used more extensively in plant operations to leverage real-
time data and mirror the physical world in a virtual model
• will allow operators to test and optimize the machine settings for the next
product in line in the virtual world before the physical changeover, thereby
driving down machine setup times and increasing quality

25. BUILDING BLOCKS
• Horizontal & Vertical Integration
• With Industry 4.0, companies, departments, functions, and capabilities will
become much more cohesive, as cross-company, universal data-integration
networks evolve and enable truly automated value chains
• Industrial Internet of Things
• Industry 4.0 means that more devices—sometimes including unfinished
products—will be enriched with embedded computing
• This will allow 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.

26. BUILDING BLOCKS
• Cyber Security
• With the increased connectivity and use of standard communications protocols that
come with Industry 4.0, the need to protect critical industrial systems and
manufacturing lines from cyber security threats increases dramatically
• As a result, secure, reliable communications as well as sophisticated identity and
access management of machines and users are essential
• The Cloud
• More production-related undertakings will require increased data sharing across
sites and company boundaries
• At the same time, the performance of cloud technologies will improve, achieving
reaction times of just several milliseconds
• As a result, machine data and functionality will increasingly be deployed to the
cloud, enabling more data-driven services for production systems

27. BUILDING BLOCKS
• Additive Manufacturing
• Companies have just begun to adopt additive manufacturing, such as 3-D
printing, which they use mostly to prototype and produce individual components
• With Industry 4.0, these additive-manufacturing methods will be widely used to
produce small batches of customized products that offer construction
advantages, such as complex, lightweight designs
• Augmented Reality
• Augmented-reality-based systems support a variety of services, such as
selecting parts in a warehouse and sending repair instructions over mobile
devices
• In future, companies will make much broader use of augmented reality to
provide workers with real-time information to improve decision making and work
procedures

28. BUILDING BLOCKS
• Big Data & Analytics
• In an Industry 4.0 context, the 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

29. INDUSTRY 4.0- EXAMPLES
• SIEMENS
• German manufacturing giant Siemens, an industrial user, is implementing an
Industry 4.0 solution in medical engineering
• For years, artificial knee and hip joints were standardized products, with
engineers needing several days to customize them for patients
• Now, new software and steering solutions enable Siemens to produce an
implant within 3 to 4 hours.

30. INDUSTRY 4.0- EXAMPLES
• TRUMPF
• German toolmaker Trumpf, an Industry 4.0 supplier and worldwide market
leader of laser systems, has put the first "social machines" to work
• Each component is "smart" and knows what work has already been carried out
on it
• Because the production facility already knows its capacity utilization and
communicates with other facilities, production options are automatically
optimized

31. INDUSTRY 4.0- EXAMPLES
• General Electric (GE)
• Predix, the operating system for the Industrial Internet, is powering digital
industrial businesses that drive the global economy
• By connecting industrial equipment, analysing data, and delivering real-time
insights, Predix-based apps are unleashing new levels of performance of both
GE and non-GE assets

32. EXAMPLES OF PRODUCT EVOLUTION:
CONNECTED AND SMART PRODUCTS

33. RESOURCES
1. Saurabh Vaidya, Prashant Ambad, Santosh Bhosle, Industry 4.0 – A
Glimpse, Procedia Manufacturing, Volume 20, 2018, Pages 233-238, ISSN
2351-9789, https://doi.org/10.1016/j.promfg.2018.02.034
2. Li Da Xu, Eric L. Xu & Ling Li (2018) Industry 4.0: state of the art and
future trends, International Journal of Production Research, 56:8, 2941-
2962, DOI: https://doi.org/10.1080/00207543.2018.1444806
3. https://www.cleverism.com/industry-4-0-everything-need-know/
4. https://www.i-scoop.eu/industry-4-0/
5. https://www.bcg.com/en-in/capabilities/operations/embracing-industry-4.0-
rediscovering-growth.aspx

35. https://www.intel.ca/content/www/ca/en/education/highered/cyber-
physical-systems-video.html

36. THANK YOU