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The Key Components of Industry 4.0 and Their Applications

Bhagyashri Kambale | February 11, 2022 | 694 views
THE KEY COMPONENTS OF INDUSTRY 4.0
Industry 4.0 technologies, ranging from simulation to big data, have advanced significantly during the past few years. It is critical to gaining access to real-time outcomes and data that will propel the sector to new heights of lean success. Growing industry expertise and technological applications are making all cutting-edge technologies commercially available.

However, the notion of Industry 4.0 is not straightforward. It comprises a wide range of technologies and is applied across a variety of circumstances. This article will explore some of the key components of Industry 4.0 and their application scenarios. All of them are critical components for industry to work smoothly, accurately, and effortlessly. Each individual component plays a unique role in the overall efficacy of Industry 4.0 technologies.

Industry 4.0 Components


Big Data and Analytics & Use Case

Big data analytics is one of the core components of Industry 4.0. With big data analytics, businesses may identify important correlations, patterns, trends, and preferences to help them make better decisions. In Industry 4.0, big data analytics is used in smart factories to forecast when maintenance and repair procedures are required. Manufacturers benefit from increased production efficiency, real-time data analysis, predictive maintenance optimization, and production management automation.

“Data is the new science. Big data holds the answers.”

– Pat Gelsinger, CEO at VMware

The IoT and current production systems create a lot of data that must be acted upon. That's why big data organizes data and develops insights that help businesses enhance their operations.

Big Data Use Cases 

Optimizing Warehouse Operations: Businesses may increase operational efficiency by identifying human mistakes, running quality checks, and displaying ideal production or assembly routes using sensors and portable devices.

Eliminating Bottlenecks: Big data helps identify variables that may slow the operation’s performance and diagnose the issue at an early stage and eliminate bottlenecks.

Predicting Demand: More accurate and relevant forecasts are made possible by visualizing activities beyond historical data through internal analysis (consumer preferences) and external analysis (trends and external events). This enables the business to predict demand, adjust and optimize its product portfolio.

Proactive Upkeep: By recognizing breakdowns in patterns, data-fed sensors indicate potential problems in the operation of machinery before they become breakdowns. The system notifies the equipment in order for it to react appropriately. These are only a few of the applications of big data analysis in manufacturing systems; there are several others, including enhanced security, load optimization, supply chain meanagemnt, and non-conformity analysis. 

Industrial Internet of Things (IIoT) & Use Case

The next component in the industry 4.0 components list is IIoT. By virtue of its unique characteristics, the Industrial Internet of Things (IIoT) is creating massive changes in industrial applications. It greatly improves the operational efficiency and workflow of factories by monitoring assets and processes in real time. The IIoT presents several opportunities for entrepreneurs to improve their industry exponentially.

“The Internet of Things is the game-changer for an overall business ecosystem transformation.”

– Joerg Grafe, Senior Market Analyst, IBM

IIOT Use Cases

Predictive Maintenance: Maintenance schedules are established for machines and assets that run continually. Unplanned maintenance and failures often cost over $88 million a year. Predictive maintenance can help control these overhead costs.

Sensor and device data allows predictive analytics systems to swiftly analyze current conditions, identify danger indications, send alerts, and initiate maintenance activities. For example, a pumping station motor in an ideal IoT facility may schedule maintenance if it detects irregularities in sensor data. This method saves money on routine and frequent maintenance.

Asset Tracking: Asset tracking is designed to find and track valuable assets. Industries can track assets to improve logistics, maintain inventory, and identify inefficiencies or theft.

Real-time asset tracking is vital in manufacturing. It may be used in warehouse and inventory management to keep track of the goods. This helps in finding the lost or misplaced goods in the warehouse. Industries with scattered assets may use IoT to track, monitor, and control them.

Workplace analytics: More IIoT devices mean more workflow data for organizations. Data scientists can use analytics engines to find inefficiencies and offer improved operations. Location data analysis might also reveal warehouse inefficiencies.

Remote quality monitoring:  Sensors give faster and more cost-effective information about products or processes, leading to faster and more effective actions. Industry 4.0-enabled quality monitoring systems can also be obtained from the IIoT.

Manufacturing factories can utilize IoT devices to remotely check material or product quality. It increases efficiency by allowing staff to verify many processes quickly. Similarly, real-time alarms make it easier for people to respond quickly, which lowers the risk of a failed product if left unchecked.

Because remote quality monitoring is a novel concept, there aren't any ready-made solutions or services. Developing customized IoT technology to measure certain metrics can be costly and difficult.

Cyber security & Use Case

Industrial manufacturing has one of the highest data breach costs of any sector. The Ponemon Institute's 2019 Cost of a Data Breach Report estimates the average industrial breach at $5.2 million. In May 2017, the WannaCry ransomware assault crippled several manufacturing companies, forcing some to shut down plants for days. Overall losses were in the billions.

“Cyber-Security is much more than a matter of IT.”

― Stephane Nappo

Cyber security is vital for a safer digital zone on your factory floor or in your manufacturing business. It is one of the crucial 4.0 industry components. It's essential to be mindful of the weaknesses while modernizing manufacturing. The largest risk in an open factory environment with widely distributed partners and operations is an incident that disrupts operations. No manufacturing company, or any organization, for that matter, should pursue digital transformation without including cyber security in every step and decision.  

Cyber Security Use Cases
  • Analyzing network traffic to detect patterns indicative of a possible attack
  • Detect harmful activities or insider risks
  • Response to incidents and forensics
  • Manage the risk associated with third- and fourth-party vendors
  • Identify data intrusions and compromised accounts
  • Risk management, governance, and compliance
  • Threat hunting is a technique for identifying signs of attack

Additive Manufacturing & Use Case

Additive manufacturing is a set of manufacturing processes that create a final product by layering material. Additive manufacturing reduces production and supply chain costs by enabling the rapid creation of large quantities of parts. It eliminates stock and the requirement for molds. Initially, 3D printing was utilized for prototyping and is still the rule. However, 3D printing technology has advanced; it is now more inventive than ever before.

“3D printing is going to be way bigger than what the 3D printing companies are saying.”

– Credit Suisse

Additive Manufacturing Use Cases

Parts for New Products: Porsche is 3D printing aluminum pistons for the Porsche 911 G2 RS engine. The improved product was made feasible using generative design software, aluminum powder, and 3D printer improvements. General Atomics Aeronautical Systems has teamed up with GE Additive to print a NACA inlet. The component is made via laser powder bed fusion.

Parts for the Aftermarket: Aftermarket components are defined as non-OEM (original equipment manufacturer) replacement parts. Thyssenkrupp and Wilhelmsen Marine Products have teamed up to offer 3D printed replacement components. With aged ships, the maritime sector frequently needs hard-to-find, costly, and time-consuming spare components. 3D printing spare parts near to the source reduces lead times and shipping costs.

Jigs, Fixtures, Molds and Tools: Jigs, fixtures, molds, and tools are essential in manufacturing. When one of these fails, a plant's downtime is prolonged. Jabil, a manufacturing services firm, has adopted 3D printing. They no longer have to wait weeks for tools or components. They can now produce tooling, fixtures, and manufacturing aids in-house in days, speeding up new product launches and increasing customer satisfaction.

Simulation and Virtualization & Use Case

Simulation in manufacturing systems is the process of using software to create computer models of production systems for the purpose of analyzing them and obtaining valuable information. According to syndicated research, it is the second-most popular management discipline among industrial managers.

“Simulation is the situation created by any system of signs when it becomes sophisticated enough, autonomous enough, to abolish its own referent and to replace it with itself.”

- Jean Baudrillard

Simulator software lets businesses try out new technologies and principles in a risk-free, virtual setting so they can make sure they're making the right investments.

Simulation Use Cases

Interoperability: The simulation showed how downstream work stations may use extra location data to more efficiently choose and organize work batches to satisfy client demand.

Information Transparency: Using sensor data, we may construct a virtual replica of the physical world, such as a manufacturing plant or contact center. This technology allows an operator to visually evaluate and certify products.

Technical Assistance: Simulating the use of Automated Guided Vehicles (AGVs) to accelerate traditional production and manufacturing processes. Additionally to substitute physically hard jobs such as stock moving is becoming increasingly popular.

Due to simulation's ability to capture the process time variation, it is an effective tool for validating critical design parameters. For example, the number of AGVs to purchase, the overall benefits to throughput, maintenance planning, and track layout.

Decentralized Decisions: In a high-mix, high-volume production plant, a simulation is performed to examine the feasibility of increasing a palletizer's storage capacity in order to 'rack-up' a series of basic tasks for overnight processing while reserving more complex processes for staff hours.

The simulation lets you try out a large number of test scenarios, including worst-case scenarios in which the machine becomes stuck near the start of its overnight operation.

Final Word

Industry 4.0 is a solution bundle for manufacturers to improve their manufacturing, inventory, and supply chain management. The key components mentioned above are only a few from an extensive list. There are more industry 4.0 technologies to include in the list, including digital twins, cloud, virtualization, robots, augmented reality, artificial intelligence, and more. Many of these technologies are now accessible to make future forward smart factories a reality today. Know about the uses of each component and learn how to integrate it into your digital manufacturing.

FAQ


What is industry 4.0 also called?

Industry 4.0 is also known as IIoT or smart manufacturing. It combines physical manufacturing and operations with smart digital technologies such as machine learning, and big data to create a more holistic and linked environment for manufacturing and supply chain businesses.

Why is Industry 4.0 needed?

Industry 4.0 technologies help you control and optimize your production and supply chain operations. It provides real-time data and insights to help you make better business decisions, eventually increasing the productivity and profitability of your company.

What are the four core components of industry 4.0?

In an attempt to define Industry 4.0 concept, German researchers developed a list of industry-defining components. They are: cyber-physical systems, IoT, Internet of Things, and smart factories.

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OSG Corporation

We are carrying out the manufacturing and supplying Water Purifier, Water Ionizer, Ionized Alkaline Water Vending Machine, Electrolyte Sterilization Water Generator , and Disinfection Water Generator by Mixing & Diluting. We are putting our products which are based on Environment, Health, and Hygiene out into the market.

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Amnovis Selects 3D Systems’ Dual Laser Direct Metal Printing Solution to Advance High-Reliability Applications

3D Systems | October 06, 2022

3D Systems (NYSE:DDD) announced that Amnovis, an additive manufacturing production and engineering company based in Aarschot, Belgium, has incorporated 3D Systems’ DMP Flex 350 Dual into its contract manufacturing workflow. This next-generation technology includes two lasers, which enables Amnovis to produce high-quality, highly reliable end-use parts for a variety of industrial and medical device applications. As a result of employing the DMP Flex 350 Dual solution, Amnovis is realizing enhanced productivity – at least 50% more as compared to the single laser DMP Flex 350 – and lower costs. Amnovis’ founders were among the first to employ laser powder bed fusion (LPBF) technology to additively manufacture Titanium medical devices such as orthopedic and spinal implants. Incorporating the DMP Flex 350 Dual printer into its manufacturing workflow is allowing Amnovis to expand its potential for stock and patient-specific medical device innovation. This unique innovation ecosystem is also enabling Amnovis to introduce product and process enhancements that can also be utilized for highly regulated industrial applications including aerospace and high tech. The DMP Flex 350 Dual is the most recent addition to 3D Systems’ Direct Metal Printing (DMP) portfolio. This dual-laser configuration maintains the benefits of the single-laser configuration including flexible application use and quick-swap build modules, and a central server to manage print jobs, materials, settings, and maintenance for 24/7 productivity. Additionally, the company’s unique vacuum chamber significantly reduces argon gas consumption while delivering best-in-class oxygen purity (<30 ppm). The printer also includes Oqton’s 3DXpert — the all-in-one software for industrial additive manufacturing that enables efficient preparation, optimization, and 3D printing of high-quality parts by streamlining the workflow from design to printing. The DMP Flex 350 Dual is designed to help accelerate innovation for a variety of applications including medical devices, aerospace, turbomachinery, semiconductors, and automotive & motorsports. “For us, innovation benefits from material and process enhancements, as well as the ability to increase productivity, We’ve experienced a tremendous leap in 3D printing efficiency by integrating 3D Systems’ DMP Flex 350 Dual into our workflow. By scaling our high-end parts manufacturing for quality-critical applications in medical, high tech, and other industries, we ensure faster delivery at lower cost, while maintaining our high-quality standards." -Ruben Wauthle, CEO and co-founder, Amnovis. In order for our service bureau customers to gain a competitive advantage, they need to differentiate the services they provide while becoming increasingly responsive to customer requirements, said Scott Anderson, vice president, segment leader, 3D Systems. Our collaboration with Amnovis is yet another example of how we can apply our application development expertise and a broad range of integrated additive manufacturing solutions to help maximize productivity, reliability, uptime, and yield. By integrating the DMP Flex 350 Dual into its solution portfolio, Amnovis is delivering high-quality parts to their customers while realizing exceptional total cost of ownership. About 3D Systems: More than 35 years ago, 3D Systems brought the innovation of 3D printing to the manufacturing industry. Today, as the leading additive manufacturing solutions partner, we bring innovation, performance, and reliability to every interaction - empowering our customers to create products and business models never before possible. Thanks to our unique offering of hardware, software, materials, and services, each application-specific solution is powered by the expertise of our application engineers who collaborate with customers to transform how they deliver their products and services. 3D Systems’ solutions address a variety of advanced applications in healthcare and industrial markets such as medical and dental, aerospace & defense, automotive, and durable goods. About Amnovis: Amnovis, based in Aarschot, Belgium, is a manufacturing and engineering company that uses innovative additive manufacturing (AM) technologies and materials for high-end applications such as medical devices. As an ISO 13485 certified contract manufacturer, Amnovis offers best-in-class AM technologies and expertise and paves the way for emerging AM technologies and materials. Digital process automation provides the traceability and repeatability to flexibly scale up manufacturing of products that comply with customer and regulatory requirements.

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MANUFACTURING TECHNOLOGY

CORE Industrial Partners Portfolio Company Cadrex Manufacturing Solutions Acquires EPMP

CADREX | October 07, 2022

CORE Industrial Partners (“CORE”), a manufacturing, industrial technology, and industrial services-focused private equity firm, announced today the acquisition of E.P.M.P., Ltd. (“EPMP” or the “Company”), a precision sheet metal fabrication services provider, by CORE portfolio company Cadrex Manufacturing Solutions (“Cadrex”). The Cadrex platform was formed in 2021 and includes ten business units with approximately 1.5 million square feet of manufacturing space and more than 2,000 employees across ten states as well as Mexico. Founded in 1984, EPMP provides high-volume sheet metal punching, forming, welding and assembly capabilities utilizing a variety of different metals, including aluminum, copper and brass, as well as carbon, galvanized and stainless steel. The Company serves a nationwide customer base in the renewable energy, HVAC, food & beverage, and industrials end markets, among others, through an equipment fleet that includes press brakes, turret punches, fiber lasers, combination laser & punch machines and automated fabrication cells. Headquartered outside San Antonio in Seguin, Texas, EPMP operates an ISO 9001-certified facility with over 50,000 square feet of manufacturing space. “EPMP’s significant historical investments in automation-driving material handling systems and robotics augment Cadrex’s high-volume sheet metal fabrication capabilities and make EPMP a highly strategic fit with the platform.” -Matthew Puglisi, Partner at CORE. Clint Plant, President of EPMP, said, For almost 40 years, EPMP has been committed to manufacturing and service excellence, demonstrating that commitment throughout all aspects of our organization. We recognize and appreciate this same customer-centric orientation at Cadrex and we’re looking forward to collaborating with Cadrex and CORE to continue our strong momentum. ABOUT CORE INDUSTRIAL PARTNERS: CORE Industrial Partners is a private equity firm with $700 million of capital commitments investing in North American lower middle-market manufacturing, industrial technology, and industrial services businesses. CORE’s team is comprised of highly experienced former CEOs and investment professionals with shared beliefs, deep experience, and a demonstrated track record of building market-leading businesses. Through our capital, insight, and operational expertise, CORE partners with management teams and strives to build best-in-class companies. ABOUT CADREX MANUFACTURING SOLUTIONS: Cadrex is a leading provider of complex production parts, assemblies, and weldments for a variety of end markets, including information communication technology, aerospace & defense, energy transmission & distribution, food production & agriculture, medical, material handling and electronic gaming & kiosk. With locations in nine states and Mexico, Cadrex offers comprehensive in-house manufacturing capabilities, including laser cutting, sheet metal fabrication, injection molding, electromechanical assembly, CNC punching, CNC machining, robotic welding, stamping, fastener insertion, and tool and die manufacturing, to effectively serve customers with lights-out manufacturing capabilities from low- through high-volume production. ABOUT EPMP: EPMP is a precision sheet metal fabrication services provider for a variety of end markets, including renewable energy, HVAC, food & beverage, and industrials. The Company offers high-volume sheet metal punching, forming, welding and assembly capabilities from an ISO 9001-certified facility outside San Antonio in Seguin, Texas.

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3D PRINTING

Fortify Ships FLUX CORE 3D Printer to IERUS Technologies

Fortify | October 06, 2022

Fortify, provider of advanced composite-photopolymer printers, announced today that IERUS Technologies received a FLUX CORE 3D printer and Flux Developer materials onboarding software for design and engineering of Defense Systems. The 3D printer will be used to realize complex RF (radio frequency) applications. "Placing a printer at the IERUS Technologies headquarters provides a critical resource to support the growing need for additive manufacturing solutions in electromagnetics for Defense, Fortify's printers are uniquely positioned to print low-loss 3D printing materials, enabling performance advantages where traditional manufacturing falls short (due to machining, weight, and size)." -Eric Versluys, Director of Defense Programs at Fortify. IERUS Technologies, a provider of engineering and design solutions for Defense and commercial customers, such as sensors and strategic systems, is designing novel RF structures such as Graded Refractive Index (GRIN) lenses leveraging Fortify's FLUX CORE system. The Flux Core system enables companies like IERUS to take advantage of the design freedoms enabled by RadixTM, a 3D printable low-loss material developed by Rogers Corporation. "The Fortify 3D printer line will enable IERUS Technologies to develop complex RF structures that push the limits of traditional RF architectures with novel electromagnetic phenomenologies." -Jason Keen, CEO of IERUS Technologies This announcement comes a few months after Fortify's strategic investment from In-Q-Tel and the development of a portfolio of electronic 3D printing materials. IERUS will leverage the FLUX Developer toolkit, an open platform for the development of viscous and filled resins, to optimize printing of RF devices. Fortify will be showcasing 3D printed RF structures printed on the FLUX CORE 3D printer at Array 2022 October 11 - 14 in Waltham, MA. About Fortify: Fortify is transforming the 3D printing industry with its patented DCM (Digital Composite Manufacturing) platform. DCM delivers new levels of additively manufactured part performance by introducing functional additives to photopolymers. By combining a deep understanding of material science with high performance mixing, magnetics, and polymer physics, Fortify is able to produce custom microstructures in high-resolution 3D printed parts. The company is currently focused on applications ranging from injection mold tooling to high performance end-use parts with unique mechanical and electromagnetic properties. Founded in 2016 and based in Boston, Fortify4 technology enables material properties and components unattainable using other additive or traditional manufacturing processes.

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ADDITIVE MANUFACTURING

Amnovis Selects 3D Systems’ Dual Laser Direct Metal Printing Solution to Advance High-Reliability Applications

3D Systems | October 06, 2022

3D Systems (NYSE:DDD) announced that Amnovis, an additive manufacturing production and engineering company based in Aarschot, Belgium, has incorporated 3D Systems’ DMP Flex 350 Dual into its contract manufacturing workflow. This next-generation technology includes two lasers, which enables Amnovis to produce high-quality, highly reliable end-use parts for a variety of industrial and medical device applications. As a result of employing the DMP Flex 350 Dual solution, Amnovis is realizing enhanced productivity – at least 50% more as compared to the single laser DMP Flex 350 – and lower costs. Amnovis’ founders were among the first to employ laser powder bed fusion (LPBF) technology to additively manufacture Titanium medical devices such as orthopedic and spinal implants. Incorporating the DMP Flex 350 Dual printer into its manufacturing workflow is allowing Amnovis to expand its potential for stock and patient-specific medical device innovation. This unique innovation ecosystem is also enabling Amnovis to introduce product and process enhancements that can also be utilized for highly regulated industrial applications including aerospace and high tech. The DMP Flex 350 Dual is the most recent addition to 3D Systems’ Direct Metal Printing (DMP) portfolio. This dual-laser configuration maintains the benefits of the single-laser configuration including flexible application use and quick-swap build modules, and a central server to manage print jobs, materials, settings, and maintenance for 24/7 productivity. Additionally, the company’s unique vacuum chamber significantly reduces argon gas consumption while delivering best-in-class oxygen purity (<30 ppm). The printer also includes Oqton’s 3DXpert — the all-in-one software for industrial additive manufacturing that enables efficient preparation, optimization, and 3D printing of high-quality parts by streamlining the workflow from design to printing. The DMP Flex 350 Dual is designed to help accelerate innovation for a variety of applications including medical devices, aerospace, turbomachinery, semiconductors, and automotive & motorsports. “For us, innovation benefits from material and process enhancements, as well as the ability to increase productivity, We’ve experienced a tremendous leap in 3D printing efficiency by integrating 3D Systems’ DMP Flex 350 Dual into our workflow. By scaling our high-end parts manufacturing for quality-critical applications in medical, high tech, and other industries, we ensure faster delivery at lower cost, while maintaining our high-quality standards." -Ruben Wauthle, CEO and co-founder, Amnovis. In order for our service bureau customers to gain a competitive advantage, they need to differentiate the services they provide while becoming increasingly responsive to customer requirements, said Scott Anderson, vice president, segment leader, 3D Systems. Our collaboration with Amnovis is yet another example of how we can apply our application development expertise and a broad range of integrated additive manufacturing solutions to help maximize productivity, reliability, uptime, and yield. By integrating the DMP Flex 350 Dual into its solution portfolio, Amnovis is delivering high-quality parts to their customers while realizing exceptional total cost of ownership. About 3D Systems: More than 35 years ago, 3D Systems brought the innovation of 3D printing to the manufacturing industry. Today, as the leading additive manufacturing solutions partner, we bring innovation, performance, and reliability to every interaction - empowering our customers to create products and business models never before possible. Thanks to our unique offering of hardware, software, materials, and services, each application-specific solution is powered by the expertise of our application engineers who collaborate with customers to transform how they deliver their products and services. 3D Systems’ solutions address a variety of advanced applications in healthcare and industrial markets such as medical and dental, aerospace & defense, automotive, and durable goods. About Amnovis: Amnovis, based in Aarschot, Belgium, is a manufacturing and engineering company that uses innovative additive manufacturing (AM) technologies and materials for high-end applications such as medical devices. As an ISO 13485 certified contract manufacturer, Amnovis offers best-in-class AM technologies and expertise and paves the way for emerging AM technologies and materials. Digital process automation provides the traceability and repeatability to flexibly scale up manufacturing of products that comply with customer and regulatory requirements.

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