The nine pillars of Industry 4.
Forming the foundation
Many companies might have already implemented some of the technologies that form
Industry 4.0 but are only using them in isolation rather than in interconnected autonomous
systems where the technologies can co-operate and communicate freely amongst and across
each other. To stay competitive in Industry 4.0, it is important to get a good understanding of
these nine technological advancements and start evaluating how they are going to impact the
industry you are in and which benefits you might gain if you start implementing them in your
organisation.
1.0 Autonomous Robots
The utilisation of robots in manufacturing is nothing new, but with the recent
technological advancements robots are becoming more autonomous, flexible and co-
operative with the ability to tackle complex as well as common mundane tasks. They
can be monitored and operated remotely and be programmed to co-exist and operate
in the same work environment as humans. Furthermore, the average price and
maintenance costs of industrial robots have been linearly decreasing over the last 15
years (Visser 2014).
2.0 Simulation ("Digital Twin")
A Digital Twin is a exact digital copy of a plant or manufacturing facility that can
simulate real time system performance. These simulations can be based on real time
data and may include machines, humans and products. This will enable advanced
control and optimisation and early problem detection, hence improved product quality
and reduced set-up time and down time.
3.0 Cloud Computing
Many companies have already implemented some form of industrial or enterprise
could solution, and this will increase much further in Industry 4.0 since many of the
technologies that form the foundation of industry 4.0 (e.g. Digital Twin, Industrial
Internet of Things) require data sharing across machines, sites and company
boundaries. With the improvement of cloud technologies, more machine and
production data will be deployed to the cloud, which will result in better service
delivery and provide visibility and optimisation through the entire supply chain.
4.0 Additive Manufacturing (3D Printing)
Additive manufacturing builds from the ground up, compared to negative
manufacturing where material is removed from the pre-formed shape in order to build
a precision part. In Industry 4.0 additive Manufacturing such as 3D printing will be
used to produce smaller batches of customised products with light weight or complex
designs, prototypes, legacy replacement parts or high value low volume parts.
Currently , additive manufactured parts tend to be 60-80% structurally weaker than
negative manufactured parts but this will most likely change in the near future, as
additive manufacturing technologies are improving.
5.0 Augmented reality
Augmented reality is going to play an important role in industry 4.0, because it can
help us provide visual, real-time information to the right person at the right place and
in the right time. Augmented reality solutions can be used with handhold devices such
as mobile phones and tablets, or integrated in products such as glasses or helmets.
These technologies will provide more flexibility, adaptability, improvement and
competitiveness of the human factor and continuous improvement. This will also lead
to reduction in defects introduced during service and maintenance, and the time spend
on training of new employees.
6.0 Big data analytics
Big data has been a popular buzzword, which you might have come across during the
last couple of years. Companies have started collecting and analysing large data sets
with the intention of optimising production quality, savings energy, reducing
production costs etc. With the increasing number of sensors integrated into
manufacturing facilities, machines and products, we will be able to increase the
quantity as well as the quality of the data we collect. With big data analytics, we will
be able to extract valuable information out of large data set and achieve better service
and product quality, shorter lead times and reduced costs.
7.0 The Industrial Internet of Things (IIoT)
The Industrial Internet of things can be described as a network of devices that have
local intelligence, which enables communication between facility, machines, and
finished as well as unfinished products. It incorporates machines learning, big data
technology, sensors data, machine to machine communication and automation
technologies. Compared to humans, connected intelligent machines are able to collect
and process large data sets with more accuracy and consistency.
8.0 Cyber Security
With the increased connectivity in manufacturing, the risk of cyber threats and cyber
attacks will also increase. It is therefore crucial for companies operating in industry
4.0 to have focus on cybersecurity and know how they can protect their data and
minimise the related risks.
9.0 System Integration
While today's IT systems are far from being fully integrated, with Industry 4.0,
companies, departments, functions, suppliers and customers will become much more
cohesive and connected. With horizontal and vertical system integration, information
and knowledge will be able to travel seamlessly through the entire supply chain and
enhance collaboration efforts between R&D and production as well as customers and
suppliers.
