There has been a paradigm shift in the style of doing business, when it comes to newer methods of manufacturing. Business houses do not depend on long assembly line theory with hundreds of manpower working on the same. Rather, they incorporate the awesomeness of IoT and other advance data exchange mechanisms. For ambitious manufacturing concerns, industry 4.0 solutions are the best choice, as the same exceeds current trends of automation and data exchange methods. This technology is so advanced that they are rightly referred to as the “Fourth Industrial Revolution”. It encompasses CPS (cyber physical systems), which is an algorithm based mechanism that has strong integration with internet. Other important systems with which Industry 4.0 is made up of are cognitive & cloud computing, with real time connection with IoT. In other words an Industry 4.0 solution encompasses AI (artificial intelligence) and complex signal processing.
The underlying basic design of Industry 4.0 solutions
There are four basic principles on which the entire design of Industry 4.0 solution is based on, they are :-
- Inter-operation capability – This is perhaps the main design principal on which Industry 4.0 is based on and has gained such technological importance. It is the ability to interconnect different sensors and in-plant machines with IoT, with a goal of rapid data exchange.
- Cascading effect- It is the ability of Industry 4.0 to create an exact copy of the physical world by cascading data into a virtual environment. This empowers the virtual environment to gain control or alter the parameter of the physical environment.
- Rapid problem solving – The ability of the control systems of Industry 4.0 can undertake urgent decisions based on information exchange. By better data visualization techniques, this technology performs a variety of task which would be exhaustive for a human to do.
- Decentralized decision making – The advance cyber physical systems which makes up the Industry 4.0 solutions, has the ability to take decisions and perform task autonomously. Only in case of super critical decisions the event is referred to the next higher technological level.
The real use of Industry 4.0 solution
With the traditional manufacturing industry in the throes of IT transformation, intelligent robots, advanced sensors and remote action capabilities are becoming a must have for modern manufacturers. Industry 4.0 solutions are used for vertical networking of advanced production systems to turn them into smart factories. Smart factories have strong need based production system, with greater control over inventory and reduced waste generation. There is a greater synergy between marketing demands and logistics networking, making the operations smoother than ever before. The transformation of manufacturing landscape through vertical networking, leads to horizontal market development, in terms of new customer generation and increased market presence, through the establishment of global value chain creation. The good effects of Industry 4.0 are felt not only on the manufacturing process, but also on its end product or the entire product lifecycle.
Undoubtedly, the switch to Industry 4.0 gives an added advantage through increase competitiveness. It helps organization explore new possibilities by incorporating latest customer preference trends into their products. It does in-depth analysis of machine data, points out cost saving areas and addresses other production bottlenecks efficiently. However, it is important for the organization to understand the cost benefit analysis of Industry 4.0 solutions. Business houses must invest in IT infrastructure to reap the benefits of Industry 4.0. The technology provides access to individual business segments by shifting from “push to market” theory to “pull generated from market”, as per customized consumer demand. The future belongs to those, who have the power to take automated decisions based on real time machine and market data, which is facilitated by Industry 4.0. The aim is to digitize the shop floor and migrate to a dynamic lean manufacturing environment.
The tremendous impact of Industry 4.0
With the onslaught of Industry 4.0, the boundaries between the real and virtual world has blurred considerably, which has given rise to CPPS (cyber physical production system). With the help of CPPS, organizations can link their electro mechanical equipments with IT in a secured network and structured manner, like a RFID (radio frequency identification technology). This type of integration makes a machine smart, which has the capacity to share information about current stock levels and product quality parameters. Also last but not the least it can step up or down production according to demand feed from marketing department. Advanced sensors are used to link not only machines but also individuals and logistics of the business house.
It is the epitome of synergy between different departments of the business, which leads to optimum capacity utilization and monitoring. This is the level of automation that today’s smart organizations work with and strives continuously to increase the bar of competition. There has been a steady rise in the innovative methods of self optimization and problem diagnosis capabilities of Industry 4.0. It has led to technology upgradation with enhanced capabilities of early problem detection and churn out optimum solutions. Industry 4.0 has largely impacted the product lifecycles along with machine safety.