The 9 technologies behind Industry 4.0
We may just be starting to wrap our minds around Industry 4.0 and its evolutionary implications for the digital industrial worlds we work in. But hands up who can name all nine technology trends that form the building blocks underpinning Industry 4.0?
Don’t worry, you’re not alone. That’s why we’ve put together this clear guide to the nine technologies, as identified by Boston Global Group. We explain what they are, how they’re transforming industrial production and why businesses are starting to take advantage of them.
Some of the nine technologies are already used in manufacturing. But with Industry 4.0, they will work together to transform production - as isolated, optimised cells come together as a fully integrated, automated, and optimised production flow. This will lead to greater efficiencies and changing traditional production relationships between suppliers, producers and customers. Not to mention between human and machine.
In no specific order of importance, let’s take a look at the nine technologies.
1. BIG DATA AND ANALYTICS
What is it?
It is the process of examining large and varied sets of data to uncover hidden patterns, unknown correlations, market trends, customer preferences and other information that’s useful to businesses.
What is the potential?
There are still massive amounts of untapped data in the industrial world. Their analysis will:
- optimise production quality
- save energy
- improve services
- allow real-time decision-making.
An industry example:
Semiconductor manufacturer Infineon Technologies has decreased product failures by correlating single-chip data captured in the testing phase at the end of the production process with process data collected earlier. This allows them to identify patterns that help discharge faulty chips early in the production process and improve production quality.
2. AUTONOMOUS ROBOTS
What is it?
Manufacturers in many industries have long used robots to tackle complex assignments (think mechanical arms on assembly lines). But robots are evolving for even greater utility, becoming more autonomous, flexible and cooperative.
What is the potential?
Robots will eventually interact with one another and work safely side by side with humans - known as cobots. Eventually they will be able to learn from humans.
An industry example:
Industrial robot supplier, ABB, has launched a two-armed robot called YuMi® that is specifically designed to assemble products alongside humans. It includes flexible hands, parts feeding systems, camera-based part location and state-of-the-art robot control.
3. SIMULATION
What is it?
Computer simulations have been used for years to determine the best possible design for production and distribution systems.
What is the potential?
3D simulation of product development, material development and production processes will become widespread. Operators will be able to test and optimise machine settings for the next product even before production starts – reducing setup times and improving quality. Rapid testing in the virtual world will ultimately lead to faster innovation in the physical one.
An industry example:
Siemens and a German machine-tool vendor developed a virtual machine that can simulate the machining of parts using data from the physical machine. This lowers the setup time for the actual machining process by as much as 80 per cent.
4. HORIZONAL AND VERTICAL SYSTEM INTEGATION
What is it?
Horizontal integration means networking between individual machines, items of equipment or production units. Vertical integration means gaining control of different parts of the supply chain.
What is the potential?
An entire organisation will be interconnected and companies will be connected with one another. With Industry 4.0, companies, departments, functions and capabilities will become much more cohesive and cross-company, universal data-integration networks evolve and enable truly automated value chains.
An industry example:
Dassault Systèmes and BoostAeroSpace launched a collaboration platform for the European aerospace and defence industry. The platform, AirDesign, serves as a common workspace for design and manufacturing collaboration and is available as a service on a private cloud. It manages the complex task of exchanging product and production data among multiple partners.
5. THE INDUSTRIAL INTERNET OF THINGS
What is it?
A way of bringing together machines, advanced analytics and people at work. It’s the network of a multitude of devices connected by communications technologies that results in systems that can monitor, collect, exchange, analyse and deliver valuable new insights.
What is the potential?
More devices – sometimes even unfinished products – will be enriched with embedded computing. This will allow field devices to communicate and interact both with one another, and with more centralised controllers. This will:
- improve connectivity
- improve efficiency
- save time
- save money through predictive maintenance, improved safety and other operational efficiencies
- enable real-time responses
An industry example:
Bosch Rexroth, a drive-and-control-system vendor, outfitted a production facility for valves with a semi-automated, decentralized production process. Products are identified by radio frequency identification codes, and workstations “know” which manufacturing steps must be performed for each product and can adapt to perform the specific operation.
6. CYBERSECURITY
What is it?
Utilised by most businesses, cyber security is made up of technologies, processes and controls that are designed to protect systems, networks and data from cyber attacks.
What is the potential?
With the increased connectivity and use of standard communication protocols that come with Industry 4.0, cybersecurity has never been more important. Sophisticated identity and machine access management systems are essential for secure, reliable communications.
An industry example:
Worldwide spending on the Internet of Things security will increase by 28 per cent to $1.5 billion (£1bn) in 2018, according to Gartner, as organisations become increasingly aware of the need to secure connected devices.
7. THE CLOUD
What is it?
This is a way of storing and accessing data and programs over the internet. Cloud services that provide real-time information and scalability can support a multitude of devices and sensors, along with all the data they generate.
What is the potential?
More production-related processes that require increased data sharing across sites and company boundaries. At the same time, the performance of cloud technologies will improve, achieving reaction times of just several milliseconds. As a result, machine data and functionality will increasingly be deployed to the cloud.
An industry example:
Manufacturers are using the cloud to collaborate, not just internally, but with suppliers and distributors. This allows them to move at a fast pace and launch new products with more speed than ever.
8. ADDITIVE MANUFACTURING
What is it?
Otherwise known as 3D printing, additive manufacturing is a technology that has been around for at least three decades. It’s used to prototype and produce individual components.
What is the potential?
It will be widely used to produce small batches of customised products that offer construction advantages, such as complex and lightweight designs. High performance, decentralised systems will reduce transport distances and inventory management costs.
An industry example:
Aerospace companies are already using additive manufacturing to apply new designs that reduce aircraft weight, lowering their costs for raw materials such as titanium.
9. AUGMENTED REALITY
What is it?
Currently in their infancy, augmented reality-based systems support a variety of services, such as selecting parts in a warehouse and sending repair instructions over mobile devices.
What is the potential?
Companies will make much broader use of augmented reality to provide workers with real-time information to improve decision making and work procedures.
For example, worker may receive repair instructions on how to replace a particular part as they are looking at the actual system needing repair. This information may be displayed directly in the worker’s field of vision using devices such as augmented reality glasses.
An industry example:
The U.S. army now uses ‘Tactical Augmented Reality’ (TAR). It’s basically an eyepiece that enables soldiers to find the positions of friends and enemies. TAR will eventually replace night-vision goggles, as it also allows soldiers to see in the dark. It will also replace their handheld SAT NAV systems. The system is entirely wireless. The eyepiece connects to a tablet worn by the soldiers. It’s also connected to a thermal site mounted on their rifles or carbines. If a soldier points a weapon, the image of the target and details such as the distance to that target, are seen through the eyepiece.