Industry 4.0 in manufacturing: terms you need to know
Industry 4.0 technologies are already helping manufacturing businesses overcome the challenges of modern industry. From meeting increased customer demands to speeding up product development and improving shopfloor safety. The opportunities and benefits manufacturers can gain from adopting Industry 4.0 are significant.
To tap into the potential digital manufacturing holds for business models, it helps to understand the key terms. This article will define them and explain their impact on the manufacturing industry.
What is additive manufacturing?
What is artificial intelligence (AI) in manufacturing?
What is augmented reality in manufacturing?
What are as a service (aaS) models?
What is big data in manufacturing?
What is cloud computing in manufacturing?
What are cobots?
What are cyber-physical systems?
What is a digital supply chain?
What is a digital twin in manufacturing?
What is enterprise resource planning (ERP) in manufacturing?
What is a human-machine interface?
What is the Industrial Internet of Things (IIoT)?
What is a manufacturing execution system (MES)?
What is predictive maintenance in manufacturing?
What is smart manufacturing?
What is virtual reality in manufacturing?
Why should manufacturers implement Industry 4.0?
What is additive manufacturing?
Additive manufacturing is the process of creating products or prototypes by layering materials such as metals or plastics. Also known as 3D printing, the additive manufacturing process takes data from CAD or digital scanners and uses this information to create individual objects layer-by-layer.
This is unlike more traditional manufacturing methods, which sometimes require several processes to create multiple products at once. This layering process means accurate pieces can be produced quickly. However, each product can only be made one at a time, meaning 3D printing isn't as efficient as mass production methods.
What is artificial intelligence (AI) in manufacturing?
AI in manufacturing refers to the use of technology which artificially recreates the problem-solving capabilities of human workers. It also encompasses a range of technologies including machine learning and deep learning. The key definition for AI technologies in manufacturing is that they can take in and analyse data before outputting actionable solutions.
This means AI systems can solve problems, spot and predict faults or adapt to changes by learning new tasks. For example, equipment that's equipped with machine learning can detect and fix operational inefficiencies automatically, with little to no human intervention.
As a result, the benefits of AI in manufacturing include reduced machine downtime, more efficient production lines, cost savings and improved safety.
What is augmented reality in manufacturing?
Augmented reality in manufacturing is where devices are used to overlay data with real life to help human workers make more informed decisions. Often used through headsets or mobile devices, this technology places a computer-generated image into a real-world environment.
This has several uses within the manufacturing industry. For example, shop floor operators can wear a headset to get real-time data analysis about the efficiency of machinery or the manufacturing process. This enables them to make changes to improve their efficiency.
Similarly, augmented reality enables design engineers to see and test out a prototype in the real world without having to build a model. This saved manufacturing companies significant time and money in the product development process.
What are as a service (aaS) models?
As a service models are business models that provide services (often through digital technologies) to customers on a subscription basis. For manufacturers, this means they can outsource particular areas of their business to maintain efficiency while focusing on their expertise.
There are three main ‘as a service’ models that you may have come across. These are:
Infrastructure as a service (IaaS) is where key digital systems are sold via subscription. For example, data servers, storage and security.
Platform as a service (PaaS) is when businesses develop a technological base they sell to customers so they can build their own digital applications or tools.
Software as a service (SaaS) where cloud-based tools or apps are made available to customers looking to improve their productivity. For example, internal communications apps.
Manufacturing as a service (MaaS) is also a recognised model and involves manufacturers being used purely to complete production processes. For example, a customer will send over a product design and the MaaS business will manufacture them using their equipment and supply chains.
What is big data in manufacturing?
Big data refers to the way businesses collect, store and analyse their information to improve overall performance. This can include real-time data collection and analysis or long-term data-driven planning. Depending on their specific requirements, organisations need to have the correct infrastructure to be able to collect, process and use this data effectively.
can have many long-term benefits for manufacturers including effective future planning, increased productivity and lower costs.
What is cloud computing in manufacturing?
Cloud computing is a service that enables businesses to store and access their data from remote servers or data centres. This means businesses aren’t restricted to the amount of data that can be stored within their in-house infrastructure. This is essential as manufacturers upgrade their digital transformation and need to process more operational data efficiently.
Cloud computing services also enable businesses to access their data wherever they need it and reduce the chances of data loss. Increasing the overall security of their information storage.
What are cobots?
A cobot, or collaborative robot, is a robot that works directly with humans in a shared workspace. Instead of being controlled remotely, cobots work safely alongside humans in assembly lines or elsewhere on the shop floor.
Just like humans, cobots can learn and adapt to their environment. This means cobots can help human workers to increase their efficiency and keep them safer while performing difficult or physically demanding tasks.
What are cyber-physical systems?
Cyber-physical systems are when the digital and real worlds are linked together through computing technology to enable better control over actual environments. For manufacturers, this can mean installing connected devices or machinery sensors to enable real-time data to be collected and reported back to remote operators.
These operators can then monitor this data and make changes to manufacturing processes from a central control panel. This makes it easier for manufacturers to develop actionable insights that can improve their operational efficiency.
What is a digital supply chain?
A digital supply chain is when original equipment manufacturers (OEMs), product manufacturers, distributors and customers are connected via a web-based platform. This gives each stakeholder in the chain complete visibility of their materials, production and delivery processes. This is key as modern supply chains become more complex and diverse.
Supported by automation and big data, a digital supply chain can bring lots of benefits to manufacturing businesses. These include better quality control, more efficient processing and future scheduling. They will also play a key part in reporting on the carbon footprint of products, something which customers and legislators will look for in the future.
What is a digital twin in manufacturing?
Digital twins in manufacturing are computer-based simulations of real-world operations. These enable manufacturers to gain a deeper insight into the performance of their processes and equipment. Depending on a business's requirements, the development of specific products can also be tracked through entire production processes.
With digital twins, manufacturers can make continuous improvements to their operations and even stress-test their processes through simulations. This enables greater resilience, efficiency and cost savings.
What is enterprise resource planning (ERP) in manufacturing?
Enterprise resource planning (ERP) systems are used by manufacturers to keep track of their business assets, operations and processes. Alongside production, ERPs analyse wider business systems including eCommerce purchases, the energy efficiency of facilities and even employee performance.
By bringing data from across different departments together it can help teams make more informed organisational decisions. This includes improving cash flow, purchase orders and payroll. ERPs also play a key part in analysing and improving a business's carbon emissions and environmental impact.
What is a human-machine interface?
A human-machine interface is a device or software programme which enables workers to monitor equipment performance. For example, on the shop floor, a manager will be able to see the status of each machine from one place.
Operators can also wear digital glasses that give them the status of a machine as they’re working on it. This helps manufacturers to increase their safety and improve maintenance processes.
What is the Industrial Internet of Things (IIoT)?
IIoT is the term given to systems of industrial equipment that are connected to each other via the Internet. IoT technologies are at the base of the fourth industrial revolution and digital transformation in the manufacturing industry.
From accessing performance data to building a smart factory, all Industry 4.0 processes are driven by IIoT.
With machines being able to ‘talk’ to each other, otherwise known as machine-to-machine (M2M) communication, manufacturers can also benefit from increased automation. Plus, they can access a variety of operational data more easily via IIoT, enabling them to make improvements to their efficiency and safety.
What is a manufacturing execution system (MES)?
A manufacturing execution system is a software programme that tracks the performance of an entire production process.
From the cost and delivery of raw materials to the efficiency of product development and end-of-life processes. MES collects data at each stage. Decision makers can then analyse this information to optimise their plant’s production performance.
Able to scale alongside the business, MES can help businesses maintain a productive and profitable manufacturing process through data-based continuous improvement.
What is predictive maintenance in manufacturing?
Predictive maintenance (also known as preventive maintenance) gives manufacturers the ability to monitor their machine’s performance and schedule any servicing or repairs.
Machines feed back key performance to a control centre. From this, human engineers or planning systems can schedule any required maintenance. This reduces production downtime as a result of equipment failures and makes maintenance more efficient.
Predictive maintenance data also helps businesses to improve their overall equipment effectiveness (OEE). In the future, it’s hoped that machine manufacturers will have enough data to predict faults before they happen. This will eventually lead to better machine design and product quality.
What is smart manufacturing?
Smart manufacturing is when an entire manufacturing process is equipped and enhanced with digital technologies. This can range from assembly lines that use one robot on a specific task to smart factories where computers control major manufacturing processes.
Connecting the physical and digital environments, collecting and analysing performance data and enabling better communication between human workers and machines are just a few capabilities of a smart factory.
All these functions are developed with the aim of improving safety, increasing efficiency and reducing costs within manufacturing businesses.
What is virtual reality in manufacturing?
Virtual reality is where an artificial digital environment is created for humans to interact with. This is usually done through a digital headset.
In manufacturing, virtual reality helps to optimise and improve the resilience of a range of processes. In product design, it helps design engineers to see, use and analyse a prototype in its environment without having to build a physical model. On the shop floor, it helps workers to maintain machinery and configure operations in the most efficient way.
In short, by enabling manufacturers to simulate their processes, virtual reality can help them preempt any problems and maximise efficiency from the start of production.
Why should manufacturers implement Industry 4.0?
Manufacturers that have already adopted Industry 4.0 haven't just experienced business benefits but have improved services for their customers too. Alongside saving costs, improving safety and increasing efficiency, digital transformation is already enabling manufacturers like Essentra Components to deliver better products faster with a hassle-free service.
As an early adopter of Industry 4.0, Essentra Components and its experts are already using Industry 4.0 technologies and systems to continuously improve customer service. Plus, by sharing this expertise through the Knowledge Centre, the team is also helping other manufacturers adopt Industry 4.0 successfully to benefit both their business and customers.