We’re in the midst of a significant transformation regarding the way we produce products thanks to the digitization of manufacturing. This compelling transition is called Industry 4.0 – which is a representation of the fourth revolution that has occurred in manufacturing. Like the three industrial revolutions which preceded it – steam power, mass production/electricity, digital age – Industry 4.0 will transform local and global economies and create a new future for us all.
2. What Is Industry 4.0?
We’re in the midst of a significant transformation regarding the way we produce
products thanks to the digitization of manufacturing. This compelling transition is
called Industry 4.0 – which is a representation of the fourth revolution that has
occurred in manufacturing. Like the three industrial revolutions which preceded
it – steam power, mass production/electricity, digital age – Industry 4.0 will
transform local and global economies and create a new future for us all.
3. Industry 4.0 Application:
Connected machines collect a tremendous volume of data that can inform
quality performance and many other issues as well as analyze data to identify
patterns and insights that would be impossible for a human to do in a
reasonable timeframe. Industry 4.0 gives manufacturers the ability for quick
optimization, allowing efficiency by knowing what needs attention. By using data
from sensors in its equipment, an African gold mine identified problems with the
oxygen levels during leaching. Once fixed they were able to increase their yield
by 3.7%, which saved them $20 million annually, according to McKinsey &
Company.
4. Taking Industry 4.0 To A Whole New Level:
Industry 4.0 takes this concept to a whole new level – the Industrial Internet of
Things (IIoT) and cyber-physical systems. Connecting the factory floor to IIoT
software allows humans and machines to communicate with one another and
work as one unified team. With Industry 4.0 manufacturers can gather real-time
data from all parts of the manufacturing process so decisions can be made
quickly and efficiently; and automate and streamline processes, reducing waste
and increasing productivity and Overall Equipment Effectiveness (OEE).
5. Adding Machine Learning And AI:
Algorithmic solutions can benefit manufacturers by predicting the quality of their
finished goods at the start of the production process, in order to increase the chances
of producing a Golden Batch EVERY time.
Data can be analyzed to predict how well machinery is running at all times. Problems
with machinery can then be detected and fixed much faster, leading to fewer
stoppages and increased output. The activities of the operators and supervisors on
each production line can also be taken into account, their output measured and
predicted, leading to increased productivity and a more efficient factory floor.
6. What Are The Benefits?
Improved Productivity
Your production lines will also experience less downtime because of enhanced machine monitoring and
automated/semi-automated decision-making. In fact, general OEE will improve as your facility moves closer to
becoming an Industry 4.0 Smart Factory.
Improved Efficiency
Multiple areas of your production line will become more efficient as a result of Industry 4.0-related technologies.
Some of these efficiencies are mentioned above – less machine downtime as well as the ability to make more
products and make them faster.
7. Increased Knowledge Sharing And Collaborative Working
Traditional manufacturing plants operate in silos. Individual facilities are silos as are individual machines within a
facility. This results in minimal collaboration or knowledge sharing.
Industry 4.0 technologies allow your production lines, business processes, and departments to communicate
regardless of location, time zone, platform, or any other factor. This enables, for example, knowledge learned by a
sensor on a machine in one plant to be disseminated throughout your organisation.
Best of all, it is possible to do this automatically, i.e. machine-to-machine and system-to-system, without any
human intervention. In other words, data from one sensor can instantly make an improvement across multiple
production lines located anywhere in the world.
8. Flexibility And Agility
The benefits of Industry 4.0 also include enhanced flexibility and agility. For example, it is easier to scale production up or
down in a Smart Factory. It is also easier to introduce new products to the production line as well as creating opportunities
for one-off manufacturing runs, high-mix manufacturing, and more.
Makes Compliance Easier
Complying with regulations in industries like pharmaceutical and medical device manufacturing does not have to be a
manual process. Instead, Industry 4.0 technologies make it possible to automate compliance including track and trace,
quality inspections, serialisation, data logging, and more.
9. Reduces Costs
Becoming a Smart Factory does not happen overnight, and it won’t happen on its own. To
achieve it, you need to invest, so there are upfront costs. However, the cost of manufacturing at
your facilities will dramatically fall as a result of Industry 4.0 technologies, i.e. automation,
systems integration, data management, and more.
Primary drivers for these reduced costs include:
● Better use of resources
● Faster manufacturing
● Less machine and production line downtime
● Fewer quality issues with products
● Less resource, material, and product waste
● Lower overall operating costs
10. Creates Innovation Opportunities
Industry 4.0 technologies give you greater knowledge of the manufacturing process, supply chains, distribution chains,
business performance, and even the products you manufacture. This creates opportunities to innovate, whether that is
changing a business process, developing a new product, optimising a supply chain, improving OEE, and more.
Higher Revenues
Many of the above points can result in higher revenues for your production facility. For example, by fully automating your
production line and implementing other Industry 4.0 technologies, you could add a new shift with minimal staffing costs to
meet an uptick in demand or compete for a new contract.
Increased Profitability
You will achieve this Industry 4.0 benefit through many of the points above including higher revenues with reduced costs.
