The Key Components of Industry 4.0 and Their Applications

Bhagyashri Kambale | February 11, 2022 | 1183 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.

Spotlight

Curry Supply Company

Curry Supply Company is a family-owned business that was established in 1932. Over the past 85 years, Curry Supply has grown into one of America’s largest manufacturers and dealers of commercial service vehicles including mechanics trucks, service trucks, vacuum trucks, winch trucks, dump trucks, crash attenuator trucks, lube trailers, and lube skids, as well as fuel/lube trucks and water trucks for both on-road and off-road needs.

OTHER ARTICLES

Achieving Interoperability in an Industry 4.0 Factory

Article | February 11, 2020

As a part of the Industry 4.0 movement, factory engineers are increasingly adopting some form of industrial Ethernet to interconnect the machines and other equipment implementing their production processes. Ethernet has been around in multiple forms for over 40 years. Most of it serves the IT community by interconnecting PCs and other equipment to a company LAN. Because of its flexibility, Ethernet has been adapted to many industrial uses.

Read More

The Impact of Coronavirus on Electronic Manufacturing

Article | February 11, 2020

Wuhan, the epicenter of the outbreak, is considered a crucial hub in the middle of China, a place of high importance for the production of automobiles, electronics, optics, and fiber optics. Wuhan and surrounding cities in the Hubei province are currently on a government-imposed quarantine at a scale the world has never seen before, some Chinese officials have referred to the situation as warlike.

Read More

Digitalizing Your Manufacturing Ecosystem

Article | February 10, 2020

Making digitalization work for you requires an understanding of your manufacturing ecosystem. Standards - such as ISA-95 - only guide you on a journey to more deeply comprehend the workings of your unique process for manufacturing your products. A batch manufacturing ecosystem often includes campaign management. Campaign management is not mentioned in ISA-95, which only speaks generally of order processing.

Read More

4 Food and Beverage Manufacturing Trends on Tap for 2020

Article | February 10, 2020

It’s the food and beverage industry’s job to appeal to consumer tastes by keeping tabs on what’s hot and what’s not. In the 1990s, for instance, fat free or reduced fat was all the rage, evidenced by the variety of products with such descriptions featured in bold typeface on cartons, cardboard and boxes. Fast forward to today, thanks in part to advancements in nutrition science, fat is back and is recommended in low-carb diets such as Atkins and Keto.

Read More

Spotlight

Curry Supply Company

Curry Supply Company is a family-owned business that was established in 1932. Over the past 85 years, Curry Supply has grown into one of America’s largest manufacturers and dealers of commercial service vehicles including mechanics trucks, service trucks, vacuum trucks, winch trucks, dump trucks, crash attenuator trucks, lube trailers, and lube skids, as well as fuel/lube trucks and water trucks for both on-road and off-road needs.

Related News

INDUSTRIAL 4.0

HNA.Live Launches AI and 3D Cloud Solution for Manufacturers

HNA Live | December 21, 2022

HNA Live, a data analytics company serving manufacturing and real estate industries, has selected CLEA, AI/IOT platform from SECO MIND USA LLC for their innovative cloud solution that combines AI and 3D technology to optimize manufacturing facility productivity. Manufacturing 4.0 is transforming the way manufacturers manage and optimize their operations, from product design and production to distribution and customer satisfaction. HNA LIVE offers granular, privacy-protected, real-time insights into the performance efficiencies and bottlenecks of operations, safety, and quality in the manufacturing space. "The digital transformations are notoriously difficult to scale up across networks of factories, the pressure to succeed is intense. With CLEA we can rapidly enable manufacturers to capture benefits across the entire manufacturing value chain." Cooper Mojsiejenko, Chief Executive Officer at HNA Live HNA Live makes use of LIDAR and other data collection technologies to precisely measure and create 3D models for manufacturing whether it's plant movement, working parts in process, or a building's entire operation. HNA.Live's cutting-edge technology provides more accurate real-time 3D modeling for a manufacturer's business strategy. "CLEA enables connecting and cloud managing any hardware for smart control, monitoring, and actionable insights. HNA Live is enabling manufacturers to increase production capacity, reduce material losses, improve delivery lead times, and reduce their environmental impact. We are very excited to be part of their journey." Ajay Malik, CEO of SECO Mind USA HNA Live HourNationArchive, INC. is a privately held company located in Denver, CO. HNA Live is a cloud solution that combines AI and 3D technology to optimize manufacturing facility productivity. Connecting LIDAR and other data collection technologies to precisely measure and create 3D models for manufacturing whether it's plant movement, working parts in process, or a building's entire operation. HNA.Live's cutting-edge technology provides more accurate real-time 3D modeling for a manufacturer's business strategy. SECO Mind USA Secomind USA LLC is a privately held company located in the heart of Silicon Valley and is a subsidiary of SECO SpA. Secomind delivers AI/IoT software for accelerating digital transformation. It builds turnkey solutions for Vending Machines, Agriculture, Defense, Manufacturing, and Healthcare. Secomind is on a mission to augment the abilities of machines and people by using AI everywhere computing takes place and is a leader in self-supervised learning, incremental learning and reinforcement learning. They have built and deployed AI products for computer vision, air quality, predictive maintenance, vending machines, defense against drones, and more for private, public, and government.

Read More

MANUFACTURING TECHNOLOGY

Matterport’s Digital Twin Platform to Support John Deere’s Worldwide Operations

Matterport | February 01, 2023

Leading spatial data firm, Matterport,Inc., recently announced the selection of its 3D capture technology and Digital Twin Platform by John Deere. The implementation allow remote management of over 60 John Deere’s facilities spread across South America, North America, Asia and Europe via a virtual operation center. The company’s platform will create digital replicas of John Deere’s manufacturing facilities, allowing teams to collaborate, plan the site changes, and track progress. To enhance site operations, John Deere will take 4K resolution digital twins with spatial accuracy using Matterport's Pro2 and Pro3 cameras. Employees at John Deere can remotely access any facility's digital twin using Matterport's digital twin technology in order to track materials and assets, keep an eye on vehicles, and integrate real-time IoT data streams. Within the digital twin, real-time collaboration increases productivity while lowering the need for expensive site visits. Jay Remley, Matterport’s Chief Revenue Officer, said, “We’re proud to support John Deere on their journey to reinvent manufacturing operations.” He further added, “For global businesses with facilities spread across several regions and time zones, the ability to remotely optimize each space based on its own unique parameters is a critical unlock for operations management. Our digital twin platform enables companies to reap real productivity gains and cost savings by digitizing their operations for more efficient maintenance, remote monitoring and improved decision making.” (Source - GlobeNewswire) About Matterport Matterport is leading spatial data solutions provider. The solutions are targeted at indexing and digitizing the built environment. Using a digital twin, enterprises can transform their built spaces into immersive, accurate digital twins to create, plan, comprehend, operate and promote any environment with Matterport’s proprietary 3D data platform. The spatial computing platform helps convert build structures into data, using every location and enhancing the overall value.

Read More

ADDITIVE MANUFACTURING,3D PRINTING

3DEO Announces the Launch of 316L Austenitic Stainless Steel

3DEO Inc. | January 30, 2023

3DEO, the leading design, engineering, and manufacturing organization known as the world's highest-volume metal 3D printing service, recently announced the launch of 316L austenitic stainless steel. The material is now accessible to customers in all industries, particularly medical, industrial, marine, and food processing. 316L (equivalent to UNS S31603) is an entirely austenitic, non-magnetic stainless steel with outstanding ductility and mechanical performance. It maintains excellent performance at both room and moderately elevated temperatures. In addition, this weldable material is highly corrosion-resistant, making it perfect for use in harsh environments. 316L is typically used for impellers and pumps, laboratory equipment, engine parts, jewelry, food processing equipment, kitchen appliances, surgical instruments, marine, chemical, and petrochemical processing, among other uses. 3DEO assists customers with complex metal components at all product life cycle stages, from early conception and prototyping to large-scale manufacturing. Since prototypes are produced on the same machinery and technology as more extensive production runs, customers can smoothly transition from prototype to production with 3DEO without requiring lengthy or costly design revisions or requalifications to launch products. Along with 17-4PH stainless steel, 316L marks the latest expansion to the company's materials division, with a growing number of new materials being tested and set to release in 2023. One of such metals in development is pure copper, which will be available in Q2. About 3DEO Founded in 2016, 3DEO is one of the world's highest-volume metal 3D printing companies. It is a differentiated service provider offering its customers trustworthy end-to-end solutions using its proprietary technology. It manufactures 3D-printed precision metal components with Intelligent Layering®, its patented metal 3D printing technique. 3DEO distinguishes itself from other manufacturers with its collaborative partnership approach to early-stage design, proprietary technology, and experience in complicated geometries and design for additive manufacturing (DfAM). In addition, the company developed the Manufacturing Cloud™, an end-to-end manufacturing platform designed to mass-produce its proprietary metal 3D printers using 3D printing, software, robotics, augmented reality, automation, and materials innovation.

Read More

INDUSTRIAL 4.0

HNA.Live Launches AI and 3D Cloud Solution for Manufacturers

HNA Live | December 21, 2022

HNA Live, a data analytics company serving manufacturing and real estate industries, has selected CLEA, AI/IOT platform from SECO MIND USA LLC for their innovative cloud solution that combines AI and 3D technology to optimize manufacturing facility productivity. Manufacturing 4.0 is transforming the way manufacturers manage and optimize their operations, from product design and production to distribution and customer satisfaction. HNA LIVE offers granular, privacy-protected, real-time insights into the performance efficiencies and bottlenecks of operations, safety, and quality in the manufacturing space. "The digital transformations are notoriously difficult to scale up across networks of factories, the pressure to succeed is intense. With CLEA we can rapidly enable manufacturers to capture benefits across the entire manufacturing value chain." Cooper Mojsiejenko, Chief Executive Officer at HNA Live HNA Live makes use of LIDAR and other data collection technologies to precisely measure and create 3D models for manufacturing whether it's plant movement, working parts in process, or a building's entire operation. HNA.Live's cutting-edge technology provides more accurate real-time 3D modeling for a manufacturer's business strategy. "CLEA enables connecting and cloud managing any hardware for smart control, monitoring, and actionable insights. HNA Live is enabling manufacturers to increase production capacity, reduce material losses, improve delivery lead times, and reduce their environmental impact. We are very excited to be part of their journey." Ajay Malik, CEO of SECO Mind USA HNA Live HourNationArchive, INC. is a privately held company located in Denver, CO. HNA Live is a cloud solution that combines AI and 3D technology to optimize manufacturing facility productivity. Connecting LIDAR and other data collection technologies to precisely measure and create 3D models for manufacturing whether it's plant movement, working parts in process, or a building's entire operation. HNA.Live's cutting-edge technology provides more accurate real-time 3D modeling for a manufacturer's business strategy. SECO Mind USA Secomind USA LLC is a privately held company located in the heart of Silicon Valley and is a subsidiary of SECO SpA. Secomind delivers AI/IoT software for accelerating digital transformation. It builds turnkey solutions for Vending Machines, Agriculture, Defense, Manufacturing, and Healthcare. Secomind is on a mission to augment the abilities of machines and people by using AI everywhere computing takes place and is a leader in self-supervised learning, incremental learning and reinforcement learning. They have built and deployed AI products for computer vision, air quality, predictive maintenance, vending machines, defense against drones, and more for private, public, and government.

Read More

MANUFACTURING TECHNOLOGY

Matterport’s Digital Twin Platform to Support John Deere’s Worldwide Operations

Matterport | February 01, 2023

Leading spatial data firm, Matterport,Inc., recently announced the selection of its 3D capture technology and Digital Twin Platform by John Deere. The implementation allow remote management of over 60 John Deere’s facilities spread across South America, North America, Asia and Europe via a virtual operation center. The company’s platform will create digital replicas of John Deere’s manufacturing facilities, allowing teams to collaborate, plan the site changes, and track progress. To enhance site operations, John Deere will take 4K resolution digital twins with spatial accuracy using Matterport's Pro2 and Pro3 cameras. Employees at John Deere can remotely access any facility's digital twin using Matterport's digital twin technology in order to track materials and assets, keep an eye on vehicles, and integrate real-time IoT data streams. Within the digital twin, real-time collaboration increases productivity while lowering the need for expensive site visits. Jay Remley, Matterport’s Chief Revenue Officer, said, “We’re proud to support John Deere on their journey to reinvent manufacturing operations.” He further added, “For global businesses with facilities spread across several regions and time zones, the ability to remotely optimize each space based on its own unique parameters is a critical unlock for operations management. Our digital twin platform enables companies to reap real productivity gains and cost savings by digitizing their operations for more efficient maintenance, remote monitoring and improved decision making.” (Source - GlobeNewswire) About Matterport Matterport is leading spatial data solutions provider. The solutions are targeted at indexing and digitizing the built environment. Using a digital twin, enterprises can transform their built spaces into immersive, accurate digital twins to create, plan, comprehend, operate and promote any environment with Matterport’s proprietary 3D data platform. The spatial computing platform helps convert build structures into data, using every location and enhancing the overall value.

Read More

ADDITIVE MANUFACTURING,3D PRINTING

3DEO Announces the Launch of 316L Austenitic Stainless Steel

3DEO Inc. | January 30, 2023

3DEO, the leading design, engineering, and manufacturing organization known as the world's highest-volume metal 3D printing service, recently announced the launch of 316L austenitic stainless steel. The material is now accessible to customers in all industries, particularly medical, industrial, marine, and food processing. 316L (equivalent to UNS S31603) is an entirely austenitic, non-magnetic stainless steel with outstanding ductility and mechanical performance. It maintains excellent performance at both room and moderately elevated temperatures. In addition, this weldable material is highly corrosion-resistant, making it perfect for use in harsh environments. 316L is typically used for impellers and pumps, laboratory equipment, engine parts, jewelry, food processing equipment, kitchen appliances, surgical instruments, marine, chemical, and petrochemical processing, among other uses. 3DEO assists customers with complex metal components at all product life cycle stages, from early conception and prototyping to large-scale manufacturing. Since prototypes are produced on the same machinery and technology as more extensive production runs, customers can smoothly transition from prototype to production with 3DEO without requiring lengthy or costly design revisions or requalifications to launch products. Along with 17-4PH stainless steel, 316L marks the latest expansion to the company's materials division, with a growing number of new materials being tested and set to release in 2023. One of such metals in development is pure copper, which will be available in Q2. About 3DEO Founded in 2016, 3DEO is one of the world's highest-volume metal 3D printing companies. It is a differentiated service provider offering its customers trustworthy end-to-end solutions using its proprietary technology. It manufactures 3D-printed precision metal components with Intelligent Layering®, its patented metal 3D printing technique. 3DEO distinguishes itself from other manufacturers with its collaborative partnership approach to early-stage design, proprietary technology, and experience in complicated geometries and design for additive manufacturing (DfAM). In addition, the company developed the Manufacturing Cloud™, an end-to-end manufacturing platform designed to mass-produce its proprietary metal 3D printers using 3D printing, software, robotics, augmented reality, automation, and materials innovation.

Read More

Events