INDUSTRY 4.0 is not A Product, But An Idea...

Entrence:

Every day we see how the digitalization of society becomes a reality and how industry, as part of it, does the same.What has been called INDUSTRY 4.0 is a term that refers to a new concept of operation of companies where everything is interrelated, from the physical environment with its people and machines, to the virtual one where the management applications serve to manage the business, and all this through the advanced communication systems that in recent years have evolved significantly in both speed and security to achieve a degree of integration that could hardly be expected only a few years ago.INDUSTRY 4.0 is not a product that can be acquired in the market, but a concept that needs to be implemented in organizations after analyzing their initial situation, and that has to consider the strategy of those to establish a correct implementation plan paying special attention to the people who make up our organization and who must accompany us throughout the process.It does not make sense to resist a change, which on the other hand is already a fact, but to follow this change and try to enjoy everything that in the next years will happen.

Arturo García Forcada

INDUSTRY 4.0 is  NOT something that will solve our problems…

We need to solve our problems ourselves, but INDUSTRY 4.0 can help us!

The term Industry 4.0 was defined to describe the intelligent factory, a vision of computerized manufacturing with all interconnected processes.

This is not something new  for many years many companies has been working in this direction.

DIGITAL INFORMATION

The capture, processing and analysis of digital data will allow the prediction and making of better decisions.

CONECTIVITY

The interconnection of the entire value chain through mobile or fixed high-bandwidth telecommunications networks will synchronize supply chains and shorten production times and innovation cycles.

DIGITAL ACCESS

Internet will give direct access to customers and suppliers and will allow to offer new types of services.

AUTOMATIZATION

The combination of traditional technologies with artificial intelligence will increasingly give rise to systems that function autonomously and with the ability to organize. This will reduce error rates and increase productivity.

HOW?

INDUSTRY 4.0 STRUCTURE

Hybridization of physical and digital systems:

• Sensors and cyberphysical systems
• Additive manufacturing
• Collaborative robotics
• Augmented reality
• IoT (Internet of things)

Communications and data processing:

• Cybersecurity
• Computing and cloud
• Advanced communications
• BigData

Management applications:

• Simulation
• Platforms
• Applications
• Horizontal and vertical
• integration

The most common mistakes in digitization...

WHY FOLLOW THIS PATH?

BECAUSE:

It will allow to increase efficiency in the value chain and its external relations (market, customers and suppliers)

It will allow the:

ü  Reduction of costs and increase of productivity.

ü  Improvement of traceability (product and process).

ü  Increase in quality

ü  Improvements in safety and sustainability.

It will allow the increase of jobs of higher value (more attractive, safe and comfortable).

It is the natural evolution of production systems based on the trend of technology.

It is the ONLY way and it is going to imply an important challenge for the companies.

EFFICIENCY

PEOPLE

Boston Consulting Group conducted surveys in Germany, as the most industrialized country in the EU, and through a predictive model estimated the employment impact of the new wave of innovations.

The results reveal that Industry 4.0 will increase employment in the industries, but it will have to improve the training of people, since it is a change that requires a greater intensity of capital and more qualified personnel.

The Boston Consulting Group

"Digitization will create new jobs, but it will also eliminate old ones – mostly unskilled ones. We have seen that in every structural transition to date. If the net balance is to add more jobs, we must concern ourselves with qualifications. Our goal must be to take people with us on our journey by providing them with training and development."

HENNING KAGERMANN

President

Source

How Digitization Adressed

• Creation of a team to coordinate actions related to INDUSTRY 4.0.
• Carry out a self-evaluation.
• Conduct an audit with external help (using resources with funding, if possible).
• Inform the organization (general information and specific training).
• Definition of an action plan that serves as a framework for action.
• Execution of the plan.

Hybridization of physical and digital systems...

SENSORS AND CYBERPHYSICAL SYSTEM

They provide autonomy to physical systems and allow their interrelation with the rest of the "world".

They use the information available in the virtual world, and they have the capacity to learn and evolve.

They have the ability to relate to physical objects for monitoring.

They allow the development of new solutions, such as collaborative robots, communication between vehicles or machine monitoring.

The cyberphysical systems (CPS) are the skeleton of the IoT, the indispensable technological link to merge the real world with the virtual world.

A cyber-physical system (CPS) is any device that integrates computing, storage and communication capabilities to control and interact with a physical process. CPS focuses primarily on communication, information and control, and usually works in a loop.

The cyberphysical systems of the future will far exceed those of today, improving adaptability, autonomy, efficiency, functionality, reliability, security and ease of use.

Advances in research in cyberphysical systems promise to transform our world with systems that:

• Respond more quickly (for example, avoid collision autonomously).
• Be more precise (for example, robotic surgery and manufacturing of nano-tolerance).
• Work in dangerous or inaccessible environments (for example, autonomous systems for search and rescue, fire fighting and exploration).
• Provide distributed coordination on a large scale (eg, automated traffic control).
• Provide high efficiecy (for example, null network power buildings).
• Increase human capacities and improve social welfare (for example, assistive and monitoring technologies and personalized health care).

COLLABORATIVE ROBOTICS

Pic Source: Universal Robots

Collaborative work with people in the same environment.

Low installation cost compared to industrial robots.

They allow the rapid automation of certain types of processes.

Ease of programming through learning.

Collaborative and sensitive robots against industrial robots.

Collaborative Robotics is based on the use of a new generation of robots that integrate with people in manufacturing environments, allowing robots and human personnel to work in a close manner without the security restrictions required in typical industrial robotics applications.

MOBILE ROBOTS (AIV)

Pic Source: Industry: Honeywell 

They allow the rapid automation of the logistics of certain types of processes.

Collaborative work with people in the same environment.

Low cost compared to the previous AGV system (they do not need infrastructure).

Ease of programming through learning.

ADDITIVE MANUFACTURING

Pic Source: all3dp.com

It allows the reproduction of any geometry with the advantage that the geometric complexity does not make the product more expensive.

 It allows the integration of different geometries and materials in the same object.

It makes possible the differentiation and personalization of the products without increasing the cost of the product.

It allows the integration of mechanisms in the same piece.

It is a competitive process in the manufacture of short series of products.

Additive Manufacturing, AM, professional 3D printing, additive layer manufacturing, freeform manufacturing.

ADDITIVE MANUFACTURING

• Binder Jetting (BJ)
• Electron Beam Melting (EBM)
• Fused Deposition Modeling (FDM)
• Laser Melting (LM)
• Laser Sintering (LS)
• Material Jetting (MJ)
• Photopolymer Jetting (PJ)
• Stereolithography (SL)
• Digital Light Synthesis (DLS)
• Single Pass Jetting (SPJ)
• Atomic Diffusion Additive Manufacturing (ADAM)

AUGMENTED REALITY

Volvo as been experimenting with AR. 

Simplifies the visualization of large volumes of information.

Visualize the information according to the place and time it is needed.

It allows to interact quickly and easily with the required information.

IoT / IIoT

It allows interaction between objects and their automation and integration.

It allows the interpretation of the environment and its manipulation.

It has localization capacity.

Allows identification and personalization.

It is the basis of the digitalization of society in general and the industry in particular.

The connected CPS would be the Internet of Things (IoT).

The Internet of Things (IoT) is a system of interrelated computing devices, mechanical and digital machines, objects, animals or people that have unique identifiers and the ability to transfer data through a network, without require human-to-human or human-computer interactions.

Communications
and Data Processing

Digital Enablers

The second layer of enablers groups communications and the processing of information. This second category collects information from the first, transports it, offers processing capacity and guarantees its security to make it available to the last layer of enablers, management applications. It also performs this communication in the opposite direction: from the applications to the enablers that make possible the hybridization of the physical and digital world.

CIBERSEGURIDAD

Technology to guarantee the confidentiality, integrity and availability (CIA) of the information stored and managed by the computer systems.

The computer security of the management systems is basically protected by the systems currently used.

The security of industrial computer systems does not receive, in many cases, the same treatment and since both environments are connected this generates an additional risk.

Cybersecurity has to manage both environments guaranteeing the CIA of the information of the company.

Protection of information assets, through the treatment of threats that put at risk the information that is processed, stored and transported by the information systems that are interconnected.

CLOUD COMPUTING

The large bandwidths have allowed the use of cloud services in a massive way.

The clouds can be private or public.

Charge according to use.

Flexible service.

Management integrated by the provider.

Availability of resources.

Infrastructure as a service (IaaS).

Platform as a service (PaaS).

Software as a service (SaaS).

Cloud computing is a general term to refer to anything that has to do with the provision of hosting services through the Internet. The name cloud computing was inspired by the cloud symbol that is often used to represent the Internet in images and flowcharts.

ADVANCED COMMUNICATIONS

Fixed or mobile communication infrastructures.

High capacity and scalability.

High speed and low latency.

Back-up lines.

Global coverage.

In the industry, connectivity facilitates and improves the efficiency, productivity, quality and safety of processes thanks to monitoring and management in real time (for example: traceability, predictive maintenance, energy efficiency, etc.) and new models of business by allowing the management of connected products.

BIG DATA

Volume - amount of data that is generated every second.

Speed - data in motion due to constant interconnections.

Variety of data - forms, types and sources in which data is recorded.

Veracity of the data - consistency, integrity, reliability.

Data visualization - mode in which the data is presented.

Value of data - data that is transformed into information.

Big Data is a common term under which all kinds of processing techniques for large volumes of data are grouped, apart from the analysis and classic tools. This concept encompasses many ideas and approaches, but all with a common goal: to extract valuable information from the data, so that it can be of help for decisions and business processes.

PHASES OF THE BIG DATA

Capture: The data can come from different sources: social networks, IoT, machines, users in their relationship with the company, biometrics, open data of the administration ...

Transformation: The process of extraction (E), transformation (T) and loading (L, of Load in English) -ETL consumes between 60% and 80% of the time of the projects. It includes the phases of filtering the data, enriching them, correcting and filtering and selecting the relevant data for the purpose of the project.

Storage: Given the large amount of data that is being worked on, it is necessary to have sufficient storage systems, so it is advisable to have your own data center (data processing center), use the cloud or distribute the data between different equipment using one of them as a central node. Regarding the type of storage, SQL relational databases are used if the data is structured and, if they are not, which is most frequent in big data projects, a NoSQL database with key-value storage or oriented to columns or documentary or in graph (BDOG).

Analysis: To analyze this large amount of data, it is necessary to use algorithms that extract information from them by choosing an appropriate algorithm and of course performing a good training and checking it. This analysis is done with advanced analysis techniques, machine learning and artificial intelligence.

Visualization: as important as obtaining information from the data is knowing how to present it in easy to visualize and understand formats. The new technologies also allow incredible presentations.

Action: All the work done previously does not make sense if the information and conclusions obtained are not used to act.

To carry out all these phases involved in any big data project, different knowledge is required:

• Data engineering to be able to build a robust data infrastructure.
• Data analysis to extract valuable information from them.
• Knowledge of the business to apply that information.

BIG DATA IN INDUSTRIAL PROCESS

Predictive diagnostics in maintenance: Big Data can help to identify efficiently possible behavior patterns in the data of manufacturing processes detecting potential failure modes.

Predicting quality problems: Big Data can help determine the causes of quality problems, the variability of the process and the traceability of the parts through the manufacturing process.

Advanced control systems: Big Data can help in improving the control of industrial processes by allowing the development of models of their behavior.

Supply chain: Inventory optimization.

Management

Applications

The third category is the layer of management applications, which processes the information obtained from the first two and applies intelligence to be able to use this information (bi-directional).

SIMULATION (DITIGITAL TWINS)

A digital twin is a virtual model of a process, product or service.

They allow learning in a virtual environment and transfer the knowledge to the physical.

Digital twins are becoming a business imperative.

A digital twin is a virtual model of a process, product or service. This pairing of the virtual and physical worlds allows the analysis of data and the validation of systems to analyze and solve problems before they occur, prevent downtime, develop new opportunities and even plan the future through simulations.

APPLICATIONS

• SCM (Supply Chain Management)

           MONTH / MOM.

           ERP

• CRM (Customer Relationship Management)

• FCM (Corporate Finance Management)

           ERP

• HRM (HR Management)

MANAGEMENT PLATFORMS

Many types of platforms: service management, data management, technology, etc.

Improve the management and storage of knowledge of organizations.

They reduce the number of emails and meetings.

They facilitate the interaction between the different people that are part of it, eliminating barriers.

Reinforce communication

They increase the feeling of belonging, motivation and commitment.

Management Platform or DMP (Data Management Platform, in English), generally refers to a service provided as SaaS (software as a service) that is used to collect, centralize, generate, share and activate customer data and / or suppliers.

HORIZONTAL AND VERTICAL

INTEGRATION

HORIZONTAL

• Integration of all work centers.
• Involvement of clients and suppliers in all phases of the process.
• Exchange of information throughout the supply chain.
• Intelligent communication in the management of demand, production and logistics.

VERTICAL

• Integration of all levels of the company from the plant to the market.
• Integration of IT systems at all levels.

At present, not all systems are fully integrated, lacking of cohesion between the company and the client and even within the production process.

Industry 4.0 proposes a greater linkage of all those that are part of the business ecosystem, ensuring an integration throughout the value chain and production operations.

FINAL
REFLEXION

• Digitization is an irreversible process that should not be resisted.
• Take advantage of the "push" that currently exists for the digitalization of society in general and industry in particular, participating in regional, national and European initiatives.
• Let's try to create networks at different levels that help us move more quickly in our digitization process.
• Let's look for the support of those who know.
• Promote knowledge within the company.
• Let's enjoy the changes that are coming.

Thank You for Your Attention

Arturo García Forcada

(Innovation Director Standard Profil Group)