Industry 4.

What is it?  It can increase the speed of innovation

and is very consumer centered, leading
 Label given to the gradual combination
to faster designing processes
of traditional manufacturing and
 Workers can become coordinators at
industrial practices with the increasing
the center of production, possibly
technological world around us
improving the work-life balance of the
 Includes using large-scale Machine-to-
employees
Machine and Internet of Things
 Sustainable long-term, assisting in
deployments
finding solutions for any challenges that
 Provide increases automation,
arises
improved communication and
monitoring, along with self-diagnosis Machine-to-Machine
and new levels of analysis to provide a
 Refers to direct communication
truly productive future
between devices using any
Who started Industry 4.0? communications channel, including
wired and wireless. Can include
 A German government memo released
industrial instrumentation.
way back in 2011 was one of the first
 Expansion of IP networks around the
times that ‘Industrie 4.0’ was
world has made machine to machine
mentioned
communication quicker and easier
 Angela Merkel, German chancellor,
while using less power
spoke glowingly of the concept in
January 2015 at the World Economic Internet of Things
Forum in Davos, calling ‘Industrie 4.0’
 Extension of internet connectivity into
the way that we “deal quickly with the
physical devices and everyday objects
fusion of the outline world and the
world of industrial production”  Embedded with electronics, internet
connectivity, and other forms of
Why? hardware (such as sensor), these
devices can communicate and interact
 Helps manufacturers with the current
with others over the internet, and they
challenges by becoming more flexible
can be remotely monitored and
and making reacting to changes in the
controlled
market easier
 Nine Technologies Transforming Industry
Production
Big Data and Analysis
 In the concept of Industry 4.0, machines
in a smart manufacturing plant interact
with their environments. Ordinary
machines transform into context-
aware, conscious, and self-learner
devices.
 This transformation gives these devices
the capability to process real-time data
to self-diagnose and prevent potential
disruptions in production process.
Furthermore, when such a machine is
assigned a task, it can self-calibrate and
prioritize between tasks to optimize
production quality or efficiency.
 As approaches like Industry 4.0 gain
popularity, the characteristics of data to
be analyzed change. Some processes
require high speed data whose value
diminishes over time.
 Heterogeneous IoT devices and sensors
produce unstandardized and
unstructured data.
 IT industry continuously comes up with
new models which can use distributes
architectures to process data more
quickly and efficiently. However,
available analysis methods are
insufficient to use high speed data
flowing from various sources due to
their lower level complexities and
shortcomings.
 The data analysis term refers to
utilization of business intelligence and
analytics technologies. This corresponds
to applying statistical and data mining
techniques in organizations to produce
additional business value.
 There are various open source and
commercial tools for ML and data
mining applications which have been
developed to execute popular
algorithms such as classification,
clustering, and anomaly detection.
Autonomous Robots
 Devices that are programmed to
perform tasks with little to no human
intervention or interaction.
 Can vary significantly in size,
functionality, mobility, dexterity,
intelligence and cost
 Can recognize and learn from their
surroundings and make decisions
independently
 Can be used to improve the speed and
accuracy of routine operations,
particularly in warehousing and
manufacturing spaces
 Work side-by-side with humans for
added efficiency
 As the hardware and software in
autonomous robots continues to
improve, they could provide a
competitive advantage to employers
within the next 10 years.
 Through improvements in sensors,
dexterity, artificial intelligence, and
trainability, they are becoming faster
and more sophisticated, and they now
include safety provisions that allow
them to work collaboratively with
humans
 As AI continues to advance, problem
solving and learning analytics will
enable robots to be responsive with
minimal human feedback
Simulation
 Computer simulation has become an
indispensable tool for understanding
the dynamics of business system
 Used more extensively in plant
operations to leverage real-time data
and mirror the physical world in a
 virtual model, which can include,
machines, products, and humans
 This will allow operators to test and
optimize the machine settings for the
next product in line in the virtual world
before the physical changeover,
thereby driving down machine setup
times and increasing quality.
Cybersecurity
 In the era of Industry 4.0, the
organizations are hyper connected with
Additive Manufacturing
their smart devices and smart networks
 This presents a very lucrative target for
the cyber criminals who find many easy
and insecure points into networks and
devices
 Cyber-attacks on critical infrastructure
and strategic industrial sectors have
become more frequent and
sophisticated
 These not only cause disruption in the
normal functioning of societies but
have crippling effect on the morale and
psyche of the victim countries
 As a result, secure, reliable
The Cloud
communications as well as
sophisticated identity and access
management of machines and users
are essential.
Augmented Reality
 Augmented Reality technology brings
users the chance to experience an
augmented world by overlaying virtual
information in the real world. This wat
the user can be in touch with both real
and virtual world and receive real-time
data or statistics
 For Industry 4.0, this can have several
Horizontal and Vertical System Integration
advantages.
 Can be the perfect way to represent
relevant information for technicians
and workers in the company, allowing
them to watch real time information
from the work they are performing
 Also suitable to provide technicians
information about the problem a
machine is going through, giving them
the chance to view the user guide or
even to contact an expert to receive
real time assistance
 Possibility of enhancing industrial
training and learning while reducing
risks and costs
 Additive (Manufacturing) technology
offers the ability to produce
personalized products with lower
development costs, shorter lead times,
less energy consumed during
manufacturing and less material waste
 Can be used to manufacture complex
parts, and enable manufacturers to
reduce inventory, make products on-
demand, create smaller localized
manufacturing environments, and even
reduce supply chains.
 More production-related undertakings
will require increases 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, enabling more
data-driven services for production
systems.
 When it comes to horizontal
integration, Industry 4.0 envisions
connected networks of cyber-physical
 and enterprise systems that introduce
unprecedented levels of automation,
flexibility, and operational efficiency
into production processes
 Vertical integration in Industry 4.0 aims
to tie together all logical layers within
the organization from the field layer
(i.e., the production floor) up through
R&D, quality assurance, product
management, IT, sales and marketing,
and so on. Data flows freely and
transparently up and down these layers
so that both strategic and tactical
decisions can be data-driven. The
vertically integrated Industry 4.0
enterprise gains a crucial competitive
edge by being able to respond
appropriately and with agility to
changing market signals and new
opportunities.
Industrial Internet of Things
 Industry 4.0 means that more
devices—sometimes including
unfinished products—will be enriched
with embedded computing.
 This will allow field devices to
communicate and interact both with
one another and with more centralized
controllers, as necessary
 It also decentralizes analytics and
decision making, enabling real-time
responses
Industry 4.0 in India
Why should India adopt Industry 4.0?
 Advanced analytics would help to
enhance production capacity and its
quality. The model would shift towards
prediction and prevention of defects
through data analytics
 The adoption of Robotics & automation
would shorten production cycle, reduce
time-to-market and bring inefficient
utilization of resources
 The digitization of various business
processes would lead to cost-saving and
a better experience for customer and
employees
 IoT and connectivity of machine to
people and machine to a machine
would tighten supply chain and reduce
lead times
 If Indian companies adopt Industry 4.0
across functions such as manufacturing,
supply chain, logistics and procurement,
they can enhance their operating
profits by 40% at less than 10% of the
planned capital expenditure
How is India preparing for Industry 4.0?
 India is keen on adopting Industry 4.0
and has taken several initiatives.
 According to Indian Brand Equity
Foundation (IBEF), the Government off
India plans to increase the contribution
of manufacturing sector to 25% of
Gross Domestic Product by 2025, from
the current level of 16%.
 India is also prepared to face global
competition by undertaking the Make
in India programme.
 It is also set to lead the world with
Smart Manufacturing.
 The heavy industries and public
enterprises ministry are facilitating the
establishment of four centers in the
country to help SMEs implement
Industry 4.0.
 India’s first smart factory is being set up
at Bengaluru. This smart factory
powered by data exchange in
manufacturing and the Internet of
Things (IoT). This factory is being
developed at the Indian Institute of
Sciences (IISc) Center for Product
 Design and Manufacturing (CPDM) with
funding from the Boeing Company.
 Andhra Pradesh government aims to
turn the state into an Internet of Things
(IoT) hub by 2020. The state
government plans to set up 10 IoT hubs
with the participation of the private
sector which will create 50,000 direct
employments in various IoT verticals.
Sectors in India which have adopted Industry
4.0
1. FMCG:
 The Indian FMCG sector has
started deploying Cobot or
Collaborative Robots in their
manufacturing process.
 Cobots are industrial robots
that work alongside workers in
a factory and require minimal
supervision.
 Factories with weaker
Collaborative Transformation
infrastructure and limited
workforce can leverage Cobots
to reduce lead time and do
optimum utilization of capacity
2. Telecom:
 Vodafone Business Services
provide smart IoT solutions for
connectivity across the range of
verticals such as industrial
manufacturing, automotive,
Role of Government—as facilitator
healthcare, smart city, and
utility management
3. Healthcare:
 Diabetacare’s smart
glucometers is a classic example
to demonstrate how patients
can manage their diabetes
better using IoT in the
healthcare sector
 IoT is making its presence felt in
healthcare by connecting
devices. This helps patients to
keep track of their blood sugar,
blood pressure etc.
4. Textile:
 A Mumbai-based MNC uses
intelligent plant framework to
connect all machines and
examine the rate of work and
efficiency.
 The framework allows to
reduce the wastage and
organize production flows.
5. Packaging:
 A Bengaluru-based packaging
company has connected
machines over a network that
provides a monthly dashboard
about the machines.
 It helps the company put
predictive maintenance in
place.
 Going forward, the Industry 4.0 can
transform the Indian manufacturing
sector.
 However, this change would require
collaborative effort from various key
stakeholders, including the government
and India Inc., in putting a viable
ecosystem in place
 The role is not only to extend support
to the manufacturing sector, but also
take reformative steps to c wider
adoption of technologies
 The government could propose a
proper regulatory framework, develop
competitiveness and form conductive
policy environment for an enabling
Industry 4.0 ecosystem in the country,
e.g. Germany
  Can also play a crucial role to encourage
employment and bridge the skill gaps
for successful implementation of
Industry 4.0
Steps taken by the Government of India to
promote the adoption of Industry 4.0
1. National Manufacturing Policy:
 In July 2017, the government rolled
out a new policy to push the
manufacturing share to 25% of the
GDP by consolidating Make in India
initiative, with focus on adoption of
digital platforms for Industry 4.0
2. Centre of Excellence (CoE) on IT for
Industry 4.0:
 This Centre of Excellence would act
as a knowledge centre for
entrepreneurs and start-ups,
propagating the concept of IT and
its application in Industry 4.0
3. National programme on Artificial
Intelligence:
 In the Union Budget 2018-19, the
government announced that NITI
Aayog will create a road map for
national AI programme focusing on
developing new AI applications
4. Mission on Cyber-Physical Systems:
 As per the Union Budget 2018-19,
the Department of Science and
Technology will launch CPS mission
to support establishment of Centre
of Excellence for training in
robotics, AI, digital manufacturing,
etc.
Role of the India Inc. – as architect
1. One of the key strengths in favor of
India’s foray into the Industry 4.0 era is
the country’s IT services industry
2. India’s IT expertise along with
infrastructure can now be leveraged
locally to catalyze Industry 4.0 adoption
in India
3. The IT sector is expected to play a
defining role in the Industry 4.0 era. As
a result of this, Indian IT companies are
already on the look out to bolster their
Industry 4.0 capabilities through R&D in
order to seize the latent opportunity
4. Apart from this, Indian IT majors have
also started exploring organizational
tie-ups and collaborations to develop
their Industry 4.0 capabilities and
offerings
5. Companies have started increasing their
focus in partnering with companies
from other sectors and countries to
develop new IoT and M2M solutions
relevant for Industry 4.0
Industry 4.0 in Different Countries
Canada
 Currently a hub for innovative tech
 Includes anything from block chain to AI
to complete digitalization
 Canadian government is even trialing
implementations on block chain in their
communications.
 It also has an impressive myriad of
funding opportunities for innovation
and new business
Japan
 Monopolises the number one rank as
one of WEF’s leading countries with its
current structure of production
 Strong player in manufacturing and
production
 Japan faces many societal challenges,
such as an increased ageing population.
Industry 4.0 could provide a solution
  Popularizing the idea of ‘Society 5.0’,
which aims to solve challenges by
implementing Industry 4.0 technologies
Germany
 On Japan’s level as a leading country in
industry
 The government even has its own
strategy for Industry 4.0
 Promotes digitalization, emphasizes
workers, SMEs, businesses and globality
 German companies are incentivized to
bring Industry 4.0 aspects into their
products like AI, automation, block
chain and IIoT
 Driven by ‘Plattform Industry 4.0’ who
moderate the technological and societal
exchange
Austria
 Strong driver of production
 Also boasts an Industry 4.0 scheme
similar to Germany’s
 Prioritizes interplay between industries,
joint strategies as well as scalability and
transferability
 Benefits from both a strong current
state of production as well as good
future of production
Switzerland
 Well-positioned both with its current
and future state of production
 Along with Germany, Switzerland has
resisted economic downturn over the
last few years
 Currently pioneer an Industry 2025
initiative, which aims to bring together
Swiss companies for Industry 4.0
technologies
Steps on How to Implement Industry 4.0
 The possibilities of Industry 4.0 are
endless. The challenge is how to
implement the technologies in an order
that gives the best result on the bottom
line.
 By breaking Industry 4.0 into 4 steps,
production will gradually mature into a
digital factory. The 4 steps are data
collection, digital processes, predictive
maintenance and self-adjusting
machines.
Step 1: Data Collection
 Without data collection, no data
analysis. The first step towards a digital
transformation is to collect data from
your machines. You can collect data
from e.g. PLCs and sensors.
 The data is transmitted to a piece of
specially designed IoT software via a
secure cloud solution.
 This will provide you with a clear
picture of the current status of your
production.
 Data collection and analysis will shed
light on the blind spots in your
production, and you will gain
knowledge of previously unknown
factors.
 By comparing data from 2 machines or
production sites, you will get fact-based
answers to questions that you were
unable to answer before.
Step 2: Digital Processes
 Step 2 is about digitalizing existing
production tools. LEAN and OEE are
frequently used for production
management and monitoring. Used as
analogue tools, they can be hard to
work with and the risk of errors is high.
  By digitalizing LEAN and OEE you can communicating via the IIoT system of
simply your production processes. This your company.
will make it easier to take concrete  In India, the machine may have learned
actions. When using the data collected that a speed reduction of 1/10 will
in Step 1 for recording the amount of reduce the amount of unplanned
and reasons for downtime, we will be downtime. The machine will share this
able to measure and compare the information with the machine in
efficiency of your production across Germany. The machine in Germany will
machines, production sites and time. in turn have learned that a certain
component is to be replaced more
Step 3: Predictive Maintenance
often than before. The machine will
 The ability to predict downtime and to send this information to the machine in
prevent it before it happens is the India.
essence of Step 3.
 Many companies already possess the
required knowledge, but they lack the
tools for turning their knowledge into
tangible actions. If we start out on the
right foot in Step 1, predictive
maintenance is not that far away.
 When we are able to predict downtime
caused by mechanical issues, supply
chain gaps or logistical challenges, we
will also be able to make decisions that
will prevent expensive downtime.
 This will significantly reduce the costs
for service and maintenance.

Step 4: Self-Adjusting Machine

 Step 4 is about machine-to-machine

communication.
 Try to imagine machines
communicating across locations. Two
identical machines producing the same
part in India and Germany and