Faculty of Management Studies – MBA

Course: The Digital Transformation Jan-Apr 2019

Course code: UM18MB554

Credits: 3

Assignment Type: ISA 2

Assignment Name: Term Paper on Industry 4.0.

SRN No: PES1201802279

Name: AKANKSHA GAUTAM SECTION: MBA “A

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 RUBRICS FOR EVALUATION OF - TERM PAPER
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 INDEX

SECTIONS CONTENT PAGE

NO
1 INTRODUCTION TO TOPIC 4

2 BACKGROUND OF TOPIC (Literature review) 5-12

3 APPLICATION OF THE TOPIC 13-16

(to an industry or organization of your choice)

3 DISCUSSION 17

( Future scope to organization and to society)

4 CONCLUSIONS 18

5 REFERENCES 19

Appendix – Plagiarism report

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 Introduction

Industry 4.0 is a name that is making a lot of noise in the industrial markets, it is believed to
impact and touch every single aspect of almost every industry by changing the whole product
life cycle, by providing an all new production means and the way in which businesses are run.
I4.0. in the sense of innovation and nature is the fourth big revolution known to mankind. It is
going to revolutionize production in ways that were never thought of and that is changing the
way a business is conducted.
Computers, robots, concepts of automation have all been around for over a decade or two but
the window of opportunity created by internet is so revolutionary that they provide us with cost
effective solutions allowing spectating activities, operations and procedures of the way in
which factories and its components namely men, machines, materials and even products. On
the flipside even data is viewed, collected, analyzed and utilized completely different. The
concept of I.4.0 is dependent on data and how the data is used is essentially becoming a source
of competitive advantage.
In recent years, production and manufacturing have been increasingly supported by IT enabled
instruments and machinery and its significance is unquestionable as it has reduced complex
tasks and has been giving solutions to control them effortlessly. The main focus of I4.0. is to
further improvise in terms of operational efficiency and automation. I4.0 is an umbrella name
given to a new face of an industrial setup called as a smart industry comprising of a fluid
mechanism between cloud computing, smart devices, smart manufacturing tech, bots, cyber
physical systems, internet of things and artificial intelligence to name a few. They are designed
to equip machinery, devices, processes and data to enable actions by exchange of information
thereby enabling a smart manufacturing eco system.
In this paper various elements of I4.0. will be looked into and all of them are encapsulated to
give a brief understanding of what I4.0. is all about, what benefits it provides and what does it
use along with where it is headed in the future.
Following the introduction, the paper is structured to give a background of I4.0. then the
concepts of smart manufacturing, AR, smart factories and cyber physical systems are all briefed
with their characteristics. Further for ease of understanding and to ensure applicability of the
concept of Industry 4.0. is applied into the Chinese phone manufacturing firm BBK Electronics
which is known to be housing brands like OPPO, VIVO and OnePlus.

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 Background

Industry 4.0 is the cyber-physical transformation of manufacturing. The name Industry 4.0 is
inspired by Germany's Industrie 4.0, a government initiative to promote connected
manufacturing and a digital convergence between industries, businesses and other processes
(Searcherp, 2017).

Industry 4.0 is the combination of Cyber-Physical Systems comprising smart machines, storage
systems and production facilities capable of autonomously exchanging information, triggering
actions and controlling each other independently. This facilitates fundamental improvements
to the industrial processes involved in activities like manufacturing, engineering, material
usage and supply chain and life cycle management (Cleverism, 2018).

A clear definition of Industry 4.0 is difficult to achieve, it is still complex and misleading as
few definitions declare it as full computerization in the manufacturing Industry whereas it can
also be virtualizing Industrial production. It can also be said as integration of horizontal and
vertical channels because Industry 4.0 goes beyond just the factory manufacturing and looks at
warehousing, logistics, HR and end to end chains etc. Also CPS (Cyber Physical Systems) are
also a major factor of Industry 4.0. As all these are connected evolutions it is hard to come up
with a clear cut definition.

Whereas the simple meaning of Industry 4.0 can be given as a revolution towards the way we
produce products through digitalization of manufacturing. The fourth industrial revolution
takes the automation of manufacturing processes to the next level by introduction of
customized and flexible mass production technologies. This means that machines will either
operate independently or cooperate with humans in order to create a customer-oriented
production place which constantly works on maintaining itself. The machine becomes an
independent entity for collecting data, analyzing it, and advising upon it.

The vision of fourth industrial revolution is of a smart factory and to make full use of digital
manufacturing. Like many other latest and emerging technologies in this century Industry 4.0
is not new. It is a reincarnation of a theory which employs the latest technologies to increase
efficiency. In this case it makes use of incorporating operational and informational technologies
as newest creation in the manufacturing sector.

Presently Industry 4.0 is in its infancy and has an isolated existence among industries, its fully
connected and vast form remains an unavoidable vision for the future. It is expected to be a
transformative, end-to-end digitization of the manufacturing unit. An organization’s vision of
Industry 4.0 will have a fully interoperable ecosystem of machinery and partners will be
realized across the supply chain and data will both inform and correct the course of actions.

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 Smart Manufacturing

The competitive advantage of an organization’s manufacturing unit can be clearly enhanced

with its capability to face the fluctuations and dynamics in the worldwide market. One way of
realizing this concept is the smart manufacturing systems, which is widely regarded as the next-
gen manufacturing system that is obtained by evolved models, new structure, technologies and
methodologies to transform the traditional dated manufacturing systems into smart systems.
Smart manufacturing is also known as Intelligent manufacturing. It is a broad concept of
manufacturing with its main intention to optimize production and product transactions by
making full use of advanced manufacturing and information technologies. It is often regarded
as a new manufacturing model which is based on intelligent science and tech. This helps in
upgrading the design, production equipment, management, and integration of the complete life
cycle of a typical product. The entire product life cycle can be enabled using various adaptive
decision making models, smart sensors, superior materials, smart devices, data analytics etc.
The production efficiency, quality of the product or service level will be greatly improved.

In the era of Industry 4.0, the smart manufacturing systems use SOA i.e. Service Oriented
Architecture over the Internet service to provide custom, collaborative, adaptable and re-
configurable services to the end-users, thereby enabling a highly integrated human and machine
manufacturing system. This unique integration of human machine cooperation is aimed at
establishing an ecosystem of the various manufacturing elements involved in IMS so that
organizational levels, managerial levels and technical levels can be seamlessly amalgamated.
For example, the FestoDidactic which is a cyber-physical factory, offers technical guidance,
training and qualification to large vendors across universities, and schools as part of the
German government’s Platform Industrie 4.0 strategic initiative. Here Artificial Intelligence
plays an essential role by providing typical features such as situational learning and reasoning,
and reacting. With the use of Artificial Intelligence, human involvement in an IMS i.e.
Information Management System can be minimized.

Example in a manufacturing setup can be that the materials and production components are
arranged automatically as per the compositions needed, and production processes and
manufacturing operations can be screened, monitored and controlled in real time from any
location. As the concept of Industry 4.0 continues to gain attention and recognition, random
sensing, smart interconnection, smart learning analysis, and smart decision making will be
realized ultimately. In another instance, an intelligent scheduling system can ensure jobs to be
scheduled based on AI technology and problem solvers can be offered to other users as services
in an Internet-enabled platform thereby enabling the most efficient use of human resources.

Smart manufacturing applications for entire enterprises or industries are very essential and
significant in Industry 4.0 because of which real life firms can benefit by making use of new
cutting edge technology. For the problem of production planning and scheduling an agent
oriented framework for IMS will be a suitable solution, as many manufacturing enterprises
generally involve varied functions such as manufacturing process planning and scheduling,
work place monitoring, controlling and warehouse inventory management. An agent oriented
implementation will be able to define workflow and follow the intended manufacturing logic
so that the decision making related to these functions can be taken efficiently. Taking
automation in manufacturing systems as an example, multi agent software programs can be

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used to control robots in a parallel way that are enabled by an agent based collaborative
architecture with various agents, in order to ease the implementation of smart manufacturing.
Another future implementation of intelligent manufacturing is cloud based solution, these use
cloud computing and SOA through a communication protocol over a network and they are
independent for different vendors, products and technologies to share or circulate
manufacturing resources. Several different cloud platforms are established to make full use of
available information so that efficient use of manufacturing capacities and resources can
provide services on demand to end users. Future research involves resources with advanced
sensors equipped with intelligence and can react but the question of how to convert such
resources into services and place them in a cloud-based platform is a challenging one and has
to be more stressed upon.

The roadmap path for Industry 4.0. can be divided into 4 different stages:

Digital Beginner: Industrial companies are beginners on the path and at this level the initial
digitization is first enabled in all functional divisions as well as products and service portfolios.
Acceptance is not guaranteed in this stage but it is an attempt towards I4.0.

Vertical Integrator: The second maturity stage of companies in Industry 4.0. is the vertical
integrator. Companies in this stage use embedded systems commonly known as integrated
software and it enables transmission of information via internet about the product with the
various manufacturing mediums.

Horizontal Collaborator: In the third level there is integration of the value chain with
customers and stakeholders within and outside the organization. It basically involves the
customers, suppliers
and contractors along the production line of the designed product. Coordination is better with
logistics service providers and hence create excellence with increase in quality as well. It
enhances the time for handling the processes and reduce operating costs considerably.
Acceptance is maintained throughout the functions of the organization and discrepancies are
administered with improved methods.

Digital Expert: It is in this stage that expertise is achieved by connecting all its operative and
executive processes worldwide and virtualizing almost all their processes. The important
executive procedures are improved globally according to the costs and controls specified. With
the expansion of internet solutions for industries they need a large investment.

An organization can follow many ways to achieve the title of digital champions but it is
recommended that it should be based on the existing product configuration and service as well
as on the operative and executive capacity and processes.

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 Augmented Reality

We have been hearing that AR and VR will disrupt the way people live, work and collaborate.
Nonetheless the advent of AR has proven to improve the manufacturing efficiency and has
taken an important spot in the components of Industry 4.0. AR is a term used to collectively
refer to a set of tech that allow the real world environment to be enhanced or augmented by
computer generated objects and elements. Manufacturing essentially needs real time
information exchange at all stages of the product development and manufacturing like design,
prototype, production, assembly repair and maintenance etc. AR in manufacturing is currently
driven by an overall increase in the development and adoption of wearables from Microsoft,
HoloLens and Oculus Rift. The world was in awe when Elon Musk used the hand tracking
technology while interacting with his design and this left a question if all this tech can be used
in other segments as well and the answer is a big list of utilities and hope to make processes
easier, simpler and efficient.

The recent advances in portable and wearable AR devices and the new impediments introduced
by industry 4.0 further enhance the applicability of AR to improve the productiveness making
industry one of its prominent domains for application. AR is considered as an important tool
for accelerating and improving the product and process development in industrial applications.
AR generally is aimed at improving safety and reliability of robotic systems showing the
intention of robots. It looks at reducing costs and improving performances of systems and
shows any discrepancies of real objects from the superimposing models. Thus AR will be
definitely one of the key tech of I4.0, and it will enrich the jobs of managers and supervisors
proving as one of the major tech revolutions of the decade.
It is possible to emphasize at least five areas which can majorly apply AR in the manufacturing
domain namely Training, Maintenance assembly and repair, Human Bot Collaboration,
Premise Monitoring and Product Inspection.

Training
The first application of AR in Industrial setup that anyone can probably imagined is in the
training activity. Innovative learning and training methods are always welcomed by instructors
and trainers to enhance learning experience, and various approaches to make it possible have
been deeply investigated. Multimedia content is something that has been used widely in the
form of images and videos that delivered a rich sensory experience and enhanced user machine
and user-user interaction as well but fails to provide any help at task execution. Now AR is
believed to be equipped with the supporting function during task execution as well. The
capability of AR to increase motivation and interest of the user is undeniable apart from its
ability to simulate dangerous tasks and destructive events without any actual risk. A large
number of industry domains like industrial plants, aerospace, automotive can be enabled with
AR based training. The complexity of the task can be tuned as per the skill of the trainee and
the instructor can give assistance through telepresence communication systems as they can see
the trainee’s camera framing through an integrated framework and help them identify their
mistakes without any major consequences.

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Maintenance, Assembly and Repair
Cost reduction being a key goal for many industries another strategic field for AR in
manufacturing is maintenance, repair and assembly tasks. Complexity is one of the problems
posed by this kind of tasks where the technicians might have to constantly refer to instructions
and manuals to correctly complete the assigned tasks. A high cognitive load to the technicians
is involved as there is a continuous switch of attention between the device involved in the
procedure and the manual. AR can efficiently and easily handle the separation problem posed.
AR implementation is expected to improve performances up to 30 percent and reduce costs by
up to 25 percent. AR applications consists of a set of assets that are virtual providing indications
and suggestions to the trainees. Audio tracks with instructions, animated graphic models
describe what to do and text labels provide details on the tasks. AR ensures these facilities are
available when the task is being performed unlike other methods.

Human Robot Collaboration

The capability of industrial robots is rapidly increasing along with a stronger cooperative
interaction expectation. New interfaces must be developed to enable robots to work side by
side with humans in the most natural way. A new scientific discipline called as Human Bot
Collaboration actively uses AI and innovative interfaces to create safe and trust worthy human
bot integration system. As robots cannot naturally understand the intention and emotions of
humans so that is where AR comes into picture to enhance the user’s ability to control and
understand robots in a promising way. The movements of a mobile robot, a robotic arm, the
forces applied by it are few aspects that AR can touch upon and increase its utility and
implementation. Automated Guided Vehicles can make use of AR to move flexibly rather than
a predefined trajectory path in the premises. For pick and place functions of a bot arm, using
AR a worker is not only aware of the object being taken but also which trajectory the bot with
follow thereby enabling the user to cancel wrong actions and commands before actually
executing them.

Product Control Quality

Every product goes through phases such as product conception, design and realization making
it a complex task to accomplish. Once realized, the product is inspected to check if there are
any errors during creation stage and is no different from the prototype or the estimation. It is
always efficient if the overall process is completed as fast and accurate as possible. At the end
of production, products have to be examined visually to check for unacceptable products
defects and it is an important function termed as inspection. Due to cognitive limitations of
human inspectors, the results could be ineffective if the variety of products and their details
increase. Here AR appears to be a promising tech clearly to setup a very efficient inspection
process, as it allows a direct comparison of the real product and the ideal model. Using a
wearable headset device, the operator can visualize a 3D presentation of the ideal product
directly augmented next to the inspected product.

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Facility Monitoring
Once a facility is constructed a basic control framework is implemented to the final product to
check if it is any different from what was initially planned. The traditional ways of checking
have been just fine and not good enough to give a hundred percent accuracy even with the
extensive use of laser scanners and geodetic devices. Thanks to AR it solves the issue of the
absence of an automated process to translate points measured into 3D models that could be
compared with the real environment. Crores of rupees can be saved as it can automatically
detect problems concerning pipe systems for gas, water and electricity supply. So 3D and CAD
model lay the plan into the real wall to check for overlays or deviations and then the workers
can inspect properly.

The Application of augmented reality devices in manufacturing function have had their own
share of issues like complexity in developing suitable algorithms, the device portability because
of its size, limited power handling capacity and computing capabilities and even largescale
deployment of hardware to support full AR enabled units. The devices cause stress and strain
to the uses causing another set of concerns. These factors may be negligible in the long run but
are currently restraining the market from using AR.
There are further difficulties related to data processing. In a world where everything is
constantly monitored and viewed the readiness of users to let their guard down in matters of
their privacy should be considered carefully. Data is continuously gathered from multiple
sensors positioned at various places and the data is saved and controlled. Gestures, Facial
expressions, voice commands are all stored. Data processing is becoming one of the most
discussed themes and without regulations there is high probability of this data being misused.
So authorities have to find common rules to regulate the data collected, to protect and empower
the user’s data privacy and reshape the approach of organizations towards data privacy.
Technology will soon comprise the back bone of I4.0. and will change its own way of working
by changing the nature of I4.0. itself.

To sum up the involvement of AR as a component of Industry 4.0. It is now unimaginable to

think of industry implementation by excluding AI from the picture. It was believed that 4.0.
was a concept with IOT as its core but so many emerging technologies like the AR itself are
saying that I4.0. is much more than that. It is the way how humans and machines interact, how
a network of devices can exchange data and function logical tasks as well. AI makes the
imagination of a factory with not just everything connected but also interactive in every
possible way. AR is not effective just because of its visualization process, it is how data is
visualized that creates all the magic and making it a powerful technology but surely with two
sides just like every other tech phenomenon in the present world with both positives and few
things downside as well.

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 Smart Factory
Smart factory is often regarded as a new frontier for manufacturing systems, it represents a big
leap forward from traditional automation to a completely connected and flexible system. A
smart factory is a system that is flexible enough to self-optimize performance across its network
and adapt itself to new conditions and situations by learning in real time and thereby being
capable of logically run an entire production process. It is clear that smart factory means
something much more than just simple automation. Due to powerful computing and analytical
capabilities alongside a broader ecosystem of smart and connected assets smart factories can
now enable firms to adapt to changes like shift in consumer demand, expansion plans into new
markets, new product development, new process incorporation or even real time changes to
production.
Though automation controls have existed for over a decade now, fully functional smart factory
has gained traction as a viable investment for manufacturers recently. Why implement a smart
factory now? Is a late question already and How Implement? is a question to be asked. Few
trends that are driving towards smart factories are the reasons why it is important now.
• Rapid evolution of technological capabilities: Until recent years there were limitations
in digital tech capabilities as well as controlled computing, storage and expensive
bandwidth. Such hurdles have diminished rapidly making it possible to do more as the
capabilities have become more sophisticated as well.

• Complexity in supply chain and global overview of production and demand: As

organizations have grown mostly global, production is now distributed, with various
components spread across the globe and this is coupled with fluctuations in demand
even within a segmented region, other issues like scarce resources and other shifts have
made supply chain very complex. So it is unavoidable to not transform as these
problems need solutions in the form of being more agile, connected and proactive and
smart factories are a way to go.

• Growing competitive pressures from every area: With the rise of smart tech, there is an
increase of threat from every firm regardless of its industry. A firm with data is the
richest and right leverage of this data along with innovative tech means its curtains
down to the existing players.

• Realignment of organizations: due to the increasing merge of IT and OT has made it

possible to move the decision making to the higher ups i.e. plant level decisions to
business unit or even enterprise level. This light up where inefficiencies exist and
complications. Now the data that is constantly being collected can be finally be turned
to information and insight and action with smart factories.

• Ongoing talent challenges: Greying of workforce, very competitive job market has
been one of the issues to traditional manufacturers. So it is the best time to make
investments on smart factories to mitigate the risk of worker shortage over the next
decade. However, this can create a new set of more qualified personnel to operate and
maintain these automated assets.

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 IOT (Internet of Things)

The Internet of things essentially means adding various sensors and networking tech to the
machinery and systems we on a daily basis. The real effect is it enables a rapid modification,
creating and customization in real world with low cost yet responding to customer
preferences by inter twining every small component in the product life cycle. I4.0 uses an
Intranet of Things, to enable digital manufacturing possible. All machinery, bots have
embedded sensors and generate data. IOT brings a network of all these data allowing a
seamless chain of activities. The issues like the bullwhip effect or even investigating quality
issues in supply chain can be addressed with this grand design of integrated network design.
It is the backbone for self-managing equipment and smart equipment along with enabling
strong consumer-supplier impact.
I4.0, smart factory would basically cease to exist without IOT design. IOT is making news
for being a catalyst of systematic change.

Cyber Physical Systems

Cyber Physical Systems provide the basis for creation of IOT, which combines with internet
services to make I4.0. possible. It is often defined as a transformative technology for managing
interconnected systems. It is a mechanism through which physical products and software is
closely interlinked, thereby enabling different components to interact with one another. It
involves a large number of methodologies like cybernetics theory, mechatronics, design
science and computing. High coordination and combined relationship between actual objects
and computing elements are enabled by methods like embedded systems. CPS enabled systems
contains networked interactions that are designed with input and output along with computed
services like algorithms. Therefore, a large number of sensors like touch screens, force pad
sensors and light sensors are a key component in a CPS.
Nonetheless, integrating various subsystems is expensive and time consuming. There are
several challenges in developing and designing high confidence and secure systems due to the
complexity and heterogeneity of the CPS applications. A large number of wireless networks
using sensors are supervising environmental aspects so this information can be controlled and
managed centrally for decision making. In the recent years a collaboration between engineers,
computer scientists and industry experts has accelerated the development of CPSs.
The Adoption of CPS in manufacturing systems comprises of storage systems, smart machines
and production areas capable of exchanging information, enabling actions and controlling each
other. There is no unified framework or a specific architecture of CPS as it is still in the initial
stages of development. It consists of two components a physical component and computing
part. The physical component collect data by sensing the environment and execute decisions
made by computing part and the computing part makes decisions by analyzing and processing
data from the physical part.

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 Application of Industry 4.0. in BBK Electronics

For Application of the Industry 4.0 concept, in this paper a manufacturing industry is chosen
mainly because of the versatile way in which various aspects of Industry 4.0 can be made use
of to increase efficiency, reliability and overall performance of the firm in the industry. End to
end manufacturing is a tedious task and any large size industry is burdened with a ton of
problems even in their basic core functions. So we will be encapsulating all the solutions and
key elements of I4.0 in a simple implementable solution and see how it can change a way a
manufacturing firm can run.
For this purpose, the firm chosen is BBK Electronics.

BBK electronics is a giant consumer electronics group based in Chang’an, Dongguan. It caters
to business all over the world and has a mini city like manufacturing unit spread over an area
of 10 hectares with over 17000 employees. They are known for manufacturing audio-video
home appliances, cordless phones, Blu-ray disc players, electronic dictionaries, reading
machines and headphones alongside the popular mobile phone brands like Oppo, Vivo and One
Plus as well. BBK Electronics is now in the wearables market with the increasing rise in the fit
bits and smart watches.

A summary of what can be a basic framework of BBK Electronics’ new Industry4.0.

implementation can be discussed with the figure below. It can ensure the most efficient ways
to organize material flow, sequencing its processes and even intelligently scheduling work
shifts to 17000 employees to meet the ever changing job requirements and this design mainly
focuses on:

• Innovation: Tap commercial innovation and bring them to industrial use like iPads can
be used to control almost every machine and readily access information throughout
without having the employees to loiter around and reduce inefficiency. M2M can be
enabled where engineers are connected with machines and this helps in gaining early
warnings when machinery, production or network performance is about to fall apart or
degrade.

A smart connected factory (Travis, Industry week, 2015) in action

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 • Efficiency: The gap from data center to control unit has to be reduced to collaborate
and share common goals between the production and IT department. Real time
identification of people, equipment, work in process and finished goods will help in
adjusting schedules and inventory on the go.

• Agility: Smart factory concept implementation can be done beyond the manufacturing
plant by external collaboration and connecting supply chain and distribution to create
dynamic workflows. This also ensures help and expertise are available in an instant. An
industrial Ethernet infrastructure has to be designed to improve processes of safety,
control, security, LAN and SCADA altogether in a single frame.

• Risk: Industrial Ethernet cables with secure networks have to be used to protect
processes, plans, people and cyber sabotage. Even keypad entry systems, call boxes and
security cameras need to be powered with this system. A ruggedized industrial network
will endure harsh environments as well even under extreme conditions.

Now we will be looking at the application of Industry 4.0. in BBK Electronics with
implementation of Smart manufacturing, Smart Factories, use of AR and CPS as well. The
concept of I4.0. is best utilized only if there are embedded processing products, complete
system expertise and a design that is easy to use alongside digitalization of systems to make
smarter, safer and efficient. The concept of I4.0 is driven by many factors and in this application
we will be looking at EDGE Computing, PLCs, CNC machine tools, Machine vision, Transport
and handling, Tool control, Robot control, Environmental Control, Industrial Communication
and Autonomous Guided Vehicles in the manufacturing of various products at BBK
Electronics.

Fig: Factors governing I4.0. (Source: Industry Texas)

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• Gateway/EDGE computing: This enables all components in the production floor to be
connected and controlled inside a network called as OT i.e., operational technology and
a secure gateway function is added to protect this domain from the world of
communication from outside. In order to make this happen BBK Electronics have to
upgrade to interoperate in the new IOT space from their decade old infrastructure with
mostly wired network protocols.

• Programmable Logic Controller (PLC): Currently most machines are controlled by

computers made specially called PLCs. They correspond to their single system and it
simply means there is a different PLC for different machine thereby increasing
complexity with every new machinery. BBK can use this existing tech but can still
automate many systems by connecting them through a high speed industrial Ethernet.
This enables BBK to run a factory that is an ideal dream as it perfects itself using
automated systems that learn from their mistakes and improve.

• Machine tool with CNC: BBK to enable effective predictive maintenance requires
advanced integrated circuit that covers every stage of data collection from the sensors
to cloud. Multiple network devices make use of real time information in production
planning, material procurement and support full online documentation of production
process.

• Machine Vision: Machine vision will be a very important element to enable greater
factory connectivity and check on productivity as well. The cameras can be used to
detect presence, movement and position of objects. Machine vision can also be used to
ensure quality check as worker’s fatigue is one of the main reason why defective
displays, speaker come out of the factory. So a combination of cameras and scanners
can be used to have a real time view of the production process and enables an efficient
collaboration of man and machines.

• Transport and Handling: I4.0 is characterized by fusion of many technologies, so

robotics and AI together can be a wonderful solution to functions like packaging,
tracking and transporting. So BBK can ensure activities like these along with checking
flow of raw materials, stacking articles efficiently by space planning in warehouses to
be carried out by robots.

• Tool control: Large industries often suffer from inefficient energy and power
management; electronic tools especially are always functioning even when they are not
in use. BBK Electronics can ensure that no device is using power when not in use by
tool control. So tool control ensures that the tools power up only when they are picked
to use by using sensors to identify activity or rest.

• Robot control: Robot control definitely needs a special mention as it has completely
changed the course of production function especially repetitive tasks and monotonous
jobs and have reduced costs incurred considerably. BBK can integrate a robotic arm
programmable to do more than just one function so it can be used interchangeably and
is never a dead investment. And even human bot collaboration is possible with new
sensors and safer designs.

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• Environment Control: When a manufacturing unit like BBK is considered there are
various standards that have to be maintained and it has shown that appropriate
conditions are very much important for efficient working of men and machinery as well.
Tight control of the factors affecting BBK can be maintained by automated control by
sensor readings so it ensures of consistent productivity and product quality.

• Industrial wired communication: Due to many stages of automation and constant

improvements there are hundreds of devices with different sensors and actuators and
BBK has to finally think about a common backbone like information flow at the right
speed and time so a variety of requirements from different systems are realized.

• Autonomous Guided Vehicle: BBK is the right organization to implement a new way
of transport in the factory premise using AI to find the nearest route, find right kind of
things, interact with the right people, pick right parts for other machines or humans.
BBK can use AGVs to accomplish tasks like machine loading and unloading.

• Additive Manufacturing Technology: Additive Manufacturing Technology is an

approach using CPS and it allows the phones in this case to be built in a layer by layer
trough adding material. By implementing CPS here BBK electronics can optimize the
customization level available to the customers. The manufacturing can be done
according to various trends prevailing as per customer’s choice. Example OnePlus can
constantly manufacture Avengers theme, or the Lamborghini Edition as per the demand
and not as a hit and trial method, name etching on the back of the phones are another
feature that can be enabled with additive manufacturing. This would allow a high
flexibility and customization.

• Customer service: Alongside manufacturing Industry4.0. concept can blend into

service industry as well. BBK Electronics to enable full automation has to work over
automation of its customer service as well. Therefore, CPS along with Artificial
Intelligence can be used to develop assistance agents that can automatically make calls,
answer queries and take over what a general customer service representative does.

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 Impact of Industry 4.0.

Most of the contemporary issues can be addressed by Industry4.0. Their capability to

adjust, study from data in real time and make decisions can make smart factories more
predictive, receptive and active as well. The impact of I4.0 is a vast subject altogether so
we will be trying to look at the major areas where it can be used as per the application is
concerned. So in a nutshell the areas of impact especially in an end to end manufacturing
industry like the consumer electronics. can be best summarized as follows.

Connectivity: Smart factories uninterruptedly pull traditional data with new sensors and
location based data. There is a real time collaboration with suppliers and customers as well
as inter departmental collaboration.

Optimization: Smart factories are reliable and predictable when it comes to production
capacity and increases production efficiency and asset uptime. There is minimum human
interaction when it comes to material handling and minimal cost of production.

Transparency: Metrics and functions are available to support quick and consistent decision
making. The real time linkages are provided to demand forecasting and customer order
tracking.

Proactive: Predictive anomaly identification and resolution, automated restocking and

replenishment functions, early identification of quality issues from suppliers and a real time
safety monitoring are all integral parts of a proactive production setup.

Agility: Flexible and adaptable scheduling and changeovers, implementation of product

changes to see their impact on real time, configurable factory layouts and equipment.

Industry 4.0 is the key to profitable growth keeping sustainability in mind effectiveness by
improved prediction of energy savings and reduced carbon footprint.

Logistics flexibility: I4.0 will decrease documentation, increase usability of data, ensure
cost savings, efficient order procurement, demand based manufacturing and traceability
and will decrease chances of incorrect deliveries.

Internal purchasing: Flexibility of internal purchasing is greatly impacted with a high speed
of procurements, increased usability of data, cost reduction, reduced labor costs, storage
times and smart use of economies of scale. It adds as strategic value of improved annual
input but reduced global costs and managerial costs partially and also increases sales and
reputation.

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 CONCLUSIONS

In this work on I4.0, briefing is mainly on smart factories and intelligent manufacturing,
augmented reality, the internet of things, cyber physical systems long with the application in a
consumer electronics manufacturing firm BBK Electronics.

Industry 4.0 is often regarded as a disruptive tech that paves the path for a new wave of
industrial production and manufacturing systems that will be like nothing before. It is accepted
as a fourth industrial revolution that is primarily driven by data. Whereas to an extent it is a
combination and a catalyst that made sure all existing tech are used efficiently in a cumulative
manner to provide the best results. It is more of a natural transition into the digital trend. Since
I4.0 is not a single phenomenon though disruptive it is credited to improvise on the existing
setup.

The path towards complete implementation is still quite blur and very long. New tech driven
firms and born global entities can fully be built on this concept but traditional enterprises are
still in a dilemma but are slowly implementing certain aspects into their processes so as to not
hurt the stability of the current process as the concept I4.0 is not just restricted to efficient
manufacturing in the production house but also is a fluid value chain right from the suppliers
to the end customer, it also involves all the functions and services of an organization’s
functions. I4.0 is an application of IOT to the industrial setup. It uses real time data being
collected that leads to the analysis and further decision making.

This work suggests on one side, a set of requirements, features ad issues have been identified
with each component of I4.0. and a sample framework has been developed to BBK Electronics
to make sure it goes closer to the I4.0. circle. But on the other hand due to few complexities as
the dream of I4.0 increases and penetrates new tech should be constantly being in development
to ensure more transparency, organized management and to instill confidence especially in
terms of data security.

For Industry 4.0. has to be successfully adopted, firms need to follow a planned right approach
as part of its strategy and thereby enhance the welfare of the society at large and contribute to
increase sustainability in every possible way.

To conclude, as quoted by Warren D Bennis, “The production facility of the future will only
have one employee and a dog. The job of the employee is to feed the dog and the task of the
dog will be to deter the employee to touch the automated systems”

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