Industry 4.0 and Its Relevance To Industrial Engineering.
Industry 4.0 and Its Relevance To Industrial Engineering.
Session: 2016-2017
3rd Year 2nd Semester
Department of Industrial and Production Engineering
CONTENTS
1. OBJECTIVE ........................................................................................................3
2. INTRODUCTION ...............................................................................................3
3. DESCRIPTION ...................................................................................................4
3.1. What Is Industry
3.2. Industrial Revolution
3.3. Stages Of Revolution
3.4. How Industry 4.0 Differ From Industry 3.0
3.5. Pillars Of Industry 4.0
3.6. Components Of Industry 4.0
3.7. Industry 4.0 Design Principles Relevant To Ipe
3.8. Advantages Of Industry 4.0 In The Perspective Of Industrial Engineering
3.9. Role of Industrial Engineers in Industry 4.0
3.10. Challenges Facing Industry 4.0
3.11. The Future Workforce
4. DISCUSSION ....................................................................................................17
5. CONCLUSION..................................................................................................17
6. REFERENCES ..................................................................................................18
1. OBJECTIVE
2. INTRODUCTION
Industry 4.0 is the subset of the fourth industrial revolution that concerns industry.
The fourth industrial revolution encompasses areas which are not normally classified
as industry, such as smart cities for instance.
Although the terms "industry 4.0" and "fourth industrial revolution" are often used
interchangeably, "industry 4.0" refers to the concept of factories in which machines
are augmented with wireless connectivity and sensors, connected to a system that
can visualize the entire production line and make decisions on its own.
In essence, industry 4.0 describes the trend towards automation and data exchange
in manufacturing technologies and processes which include cyber-physical systems
(CPS), the internet of things (IoT), industrial internet of things (IIOT), cloud
computing ,cognitive computing and artificial intelligence.
The concept includes:
I. Smart manufacturing
II. Smart factory
III. Lights out (manufacturing) also known as dark factories
IV. Industrial internet of things also called internet of things for manufacturing.
Industry 4.0 fosters what has been called a "smart industry". Within modular
structured smart factories, cyber-physical systems monitor physical processes,
create a virtual copy of the physical world and make decentralized decisions. Over
the Internet of Things, cyber-physical systems communicate and cooperate with
each other and with humans in real-time both internally and across organizational
services offered and used by participants of the value chain. [1]
Figure-1: Smart Industry
3. DESCRIPTION
3.7.1. Interoperability
Objects, machines and people need to be able to communicate through
the Internet of Things and the Internet of People. This is the most essential
principle that truly makes a factory a smart one.
3.7.2. Virtualization
CPSs must be able to simulate and create a virtual copy of the real world.
CPSs must also be able to monitor objects existing in the surrounding
environment. Simply put, there must be a virtual copy of everything.
3.7.3. Decentralization
The ability of CPSs to work independently. This gives room for
customized products and problem solving. This also creates a more
flexible environment for production. In cases of failure or having
conflicting goals, the issue is delegated to a higher level. However, even
with such technologies implemented, the need for quality assurance
remains a necessity on the entire process
3.7.5. Service-Orientation
Production must be customer-oriented. People and smart objects/devices
must be able to connect efficiently through the Internet of Services to
create products based on the customer’s specifications. This is where the
Internet of Services becomes essential.
3.7.6. Modularity
In a dynamic market, a Smart Factory’s ability to adapt to a new market
is essential. In a typical case, it would probably take a week for an average
company to study the market and change its production accordingly. On
the other hand, smart factories must be able to adapt fast and smoothly to
seasonal changes and market trends.
3.8.1. Optimization
Optimizing production is a key advantage to Industry 4.0. A Smart
Factory containing hundreds or even thousands of Smart Devices that are
able to self-optimize production will lead to an almost zero down time in
production. This is extremely important for industries that use high end
expensive manufacturing equipment such as the semi-conductors
industry. Being able to utilize production constantly and consistently will
profit the company. According to a study published by PwC.
3.8.2. Customization
Creating a flexible market that is customer-oriented will help meet the
population’s needs fast and smoothly. It will also destroy the gap between
the manufacturer and the customer. Communication will take place
between both directly. Manufacturers won’t have to communicate
internally (in companies and factories) and externally (to customers).
This fastens the production and delivery processes.
3.8.3. Pushing Research
The adoption of Industry 4.0 technologies will push research in various
fields such as IT security and will have its effect on the education in
particular. A new industry will require a new set of skills. Consequently,
education and training will take a new shape that provides such an
industry will the required skilled labor. [7]
Definitely Industrial engineers will have crucial roles in Industry 4.0 settings
such as designing, implementing and maintaining the enabling technologies
of a fully automated smart factory, namely cyber-physical systems.
To put it more short, the 4.0 industrial engineer has to be capable of choosing
and implementing the appropriate cyber-physical components and systems
while matching them to smart factory processes.
3.10.1. Security
Perhaps the most challenging aspect of implementing Industry 4.0
techniques is the IT security risk. This online integration will give room
to security breaches and data leaks. Cyber theft must also be put into
consideration. In this case, the problem is not individual, but can, and
probably will, cost producers money and might even hurt their reputation.
Therefore, research in security is crucial.
3.10.2. Capital
Such transformation will require a huge investment in a new technology
that doesn’t sound cheap. The decision to make such transformation will
have to be on CEO level. Even then, the risks must be calculated and
taken seriously. In addition, such transformation will require a huge
capital, which alienates smaller businesses and might cost them their
market share in the future.
3.10.3. Employment
While it still remains early to speculate on employment conditions with
the adoption of Industry 4.0 globally, it is safe to say that workers will
need to acquire different or an all-new set of skills. This may help
employment rates go up but it will also alienate a big sector workers. The
sector of workers whose work is perhaps repetitive will face a challenge
in keeping up with the industry. Different forms of education must be
introduced, but it still doesn’t solve the problem for the elder portion of
workers. This is an issue that might take longer to solve and will be
further analyzed later in this report.
3.10.4. Privacy
This not only the customer’s concern, but also the producers. In such an
interconnected industry, producers need to collect and analyze data. To
the customer, this might look like a threat to his privacy. This is not only
exclusive to consumers. Small or large companies who haven’t shared
their data in the past will have to work their way to a more transparent
environment. Bridging the gap between the consumer and the producer
will be a huge challenge for both parties.
4. DISCUSSION
5. CONCLUSION
Industry 4.0 is leading to some clearly visible and measurable benefits such as lower
costs, more efficiency, easier inventory management, lower payback time and
enhanced productivity. All this is done through the deployment of advanced
technology in a strategic and intelligent way. Benefits of this industrial revolution
can also be felt in developing nations such as India, where previous technology
breakthroughs have been skipped. The end result? Shop floor professionals and
manufacturing players get to operate in the factories of the future and improve their
business and growth while giving consumers exactly what they want.
6. REFERENCES