Industry 4.0
What is it?Industry 4.0
The first industrial revolution, which began in the late eighteenth century in the United Kingdom, helped to achieve large-scale production by replacing pure human and animal power with water and steam power. The finished product comes from machine manufacturing rather than from hard manual production.
A century later, the second industrial revolution introduced assembly lines and access to oil, gas and electricity. These new energy sources, together with more advanced communications via telephone and telegraph, have enabled large-scale production capacity and some degree of automation in the manufacturing process.
The third industrial revolution began in the middle of the twentieth century with the addition of computers and advanced telecommunications and data analysis in the manufacturing process. The programmable logic controller (PLC) is embedded in the machine to help automate certain processes and collect and share data, thereby starting to digitize the plant.
We are now in the midst of the fourth industrial revolution, also known asIndustry 4.0This is characterized by increased automation and the use of smart machines and factories, where data insight can help produce goods more efficiently across the value chain. Production flexibility has been increased and manufacturers can better meet customer needs through large-scale customizations — in many cases ultimately seeking to achieve efficiency gains through minimal production volumes. By gathering more data from factory workshops and combining them with data on the operations of other enterprises, intelligent plants can achieve transparency of information and better decision-making.
Industry 4.0How Technology Change Manufacturing
Industry 4.0The way in which companies manufacture, improve and distribute products is being radically changed. The manufacturer is going to include the Internet,Cloud New technologies, including computing and analysis and artificial intelligence and machine learning, are integrated into their production facilities and throughout their operation.
These intelligent plants are equipped with advanced sensors, embedded software and robotic techniques to collect and analyse data and make better decisions. When data from production operations and from ERP Supply chain, customersServicesWhen combined with operational data from other enterprise systems, new visibility and insight from previously isolated information can create higher value.
Industry 4.0This digital technology enhances automation, predictive maintenance, self-optimization of process improvements and, most importantly, raises efficiency and responsiveness to clients to unprecedented new levels.
The development of smart factories provides a unique opportunity for manufacturing to enter the fourth industrial revolution. The analysis of the large amounts of data collected from the sensors in the plant workshops ensures real-time visibility of the manufacturing assets and can provide tools for implementing forecasting maintenance to minimize equipment downtime.
The use of high-tech networking equipment in smart factories increases productivity and quality. The replacement of manual inspection of business models with AI-driven visual insight can reduce errors and save money and time. With a minimum investment, quality control personnel can set up connections to Cloud Smart phone to monitor the manufacturing process from almost anywhere. By applying machine learning algorithms, manufacturers can detect errors immediately, rather than at a later stage of more expensive maintenance work.
Industry 4.0Concepts and technologies could be applied to all types of industrial companies, including discrete and process manufacturing, as well as to oil and gas, mining and other industrial areas.
Which technologies are drivingIndustry 4.0Development
Networking of goods (IOT)
IoT is a key component of an intelligent factory. The machines in the workshop were equipped with sensors with IP addresses that allowed the machines to be connected to other equipment supporting the network. This mechanization and connectivity has made it possible to collect, analyse and exchange a wealth of valuable data.
Cloud Calculate
Cloud Calculate anyIndustry 4.0The cornerstone of the strategy. Full realization of smart manufacturing requires engineering, supply chain, production, marketing, distribution andServicesConnectivity and integration. Cloud Technology can help to achieve this goal. In addition, through Cloud Computation usually allows for more economical and efficient processing of the large amount of data stored and analysed. Cloud The calculation also reduces start-up costs for small and medium-sized manufacturers, which can adjust demand and scale up based on business growth.
AI and Machine Learning
AI and machine learning enable manufacturing enterprises to take full advantage of the wealth of information from factory workshops, business sectors and even from partners and third parties. AI and machine learning can provide insights to achieve visibility, predictability and automation of operations and business processes. For example, industrial machinery is prone to malfunction in the production process. The use of data collected from these assets can help businesses to implement predictive maintenance based on machine learning algorithms, thereby increasing normal operating time and efficiency.
edge calculation
The demand for real-time production operations means that some data analysis has to be done on the edge (i.e. where the data are created). This minimizes delays from data generation to response. For example, detection of safety or quality problems may require almost real-time operation of equipment. Send data to business Cloud It may take too long to return to the plant and depend on the reliability of the network. The use of edge calculations also means that the data remain close to the source, thereby reducing security risks.
Cybersecurity
Manufacturing enterprises do not always take into account cybersecurity or the importance of information physics systems. While plant or on-site operating equipment (OT) has the same connectivity that increases the efficiency of the manufacturing process, it also exposes new entry routes for malicious attacks and malware. In the transition to industry 4.0 digitize, a network security approach incorporating IT and OT equipment must be considered.
Digital Twin
Industry 4.0The resulting digital transformation enables manufacturers to createDigital Twin, i.e. virtual copies of processes, production lines, factories and supply chains. Created by extracting data from IOT sensors, equipment, PLC and other Internet networking devicesDigital Twin The manufacturer can use it.Digital TwinTo promote productivity, improve work processes and design new products. For example, by simulated production processes, manufacturers can test process changes to find ways to minimize downtime or increase capacity.
Characteristics of smart factories
Data analysis to optimize decision-making
Embedded sensors and interconnected mechanical devices generate large amounts of data for manufacturing enterprises. Data analysis helps manufacturers to investigate historical trends, identify patterns and make better decisions. Intelligent plants can also use data from other sectors of the enterprise, as well as from the extended ecosystem of suppliers and distributors, to obtain deeper insights. By looking at data from human resources, sales or warehousing, manufacturers can make production decisions based on sales profits and staffing. CreateDigital TwinA full picture of operations can be digitized. "
IT-OT Integration
The network structure of smart factories depends on connectivity. Real-time data collected from sensors, equipment and machines in plant workshops can be immediately used by other plant assets and shared among other software in enterprise software stacks, This includes ERP ERP) and other business management software.
Custom manufacture
Smart factories are able to produce custom goods that meet the needs of their clients more economically and efficiently. In fact, in many industrial areas, manufacturers are eager to achieve "minimum production batch" in an economic way. By using advanced simulation software applications, new materials and 3D printing, manufacturers can easily produce small quantities of specialized products for specific customers. The first industrial revolution was related to large-scale production, while industry 4.0 was related to large-scale customization.
Supply chain
Industrial operations depend on transparent and efficient supply chains. As a steady man.Industry 4.0As part of the strategy, supply chains must be integrated with production operations. This has changed the way manufacturers acquire raw materials and deliver finished products. By sharing some production data with suppliers, manufacturers can better arrange delivery. For example, if the assembly line is interrupted, delivery can be rescheduled or delayed to reduce time or cost wastage. In addition, by studying weather, transport partners and retailer data, enterprises can use forecasting to deliver finished products at the right time to meet consumer needs. Block chains are becoming key technologies for improving transparency in supply chains.