Rahul

INDUSTRY 4.0
In 2006, the German government presented its “High-Tech Strategy” at
Hannover Messe and after five years in 2011 Industry 4.0 originated
from a project in the high-tech strategy of the German government,
which promotes the computerization of manufacturing. Actually, the
term “Industry 4.0” was publicly introduced in the same year at the
Hannover Fair.
At the very core Industry 4.0 includes the (partial) transfer of autonomy
and autonomous decisions to cyber-physical systems and machines,
leveraging information systems.
Industry 4.0 is the information-intensive transformation of
manufacturing in a connected environment of big data, people,
processes, services, systems and IoT-enabled industrial assets with the
generation, leverage and utilization of actionable data and information as
a way and means to realize smart industry and ecosystems of industrial
innovation and collaboration. Industry 4.0 is the evolution to cyber-
physical systems, representing the fourth industrial revolution on the
road to an end-to-end value chain with Industrial IoT and decentralized
intelligence in manufacturing.

Ashutosh
It’s here that Industrie 4.0 was first mentioned in a clear
relationship with the advent of a fourth industrial revolution, driven
by the Internet and the Internet of Things. The characteristics of the
industrial production of the future as follows:
A high degree of individualization (personalization) of products with a
highly flexible production;
The early inclusion/involvement of customers and business partners in
design and value creation processes;

Priya
Connecting production and high-quality services which would lead to
so-called hybrid products.
The government expressed its intention to support the business and
science community to develop and implement Industrie 4.0 with
additional focus on security and the impact on labor and employment.
Other digital priorities included smart services, smart data, cloud
computing, digital/intelligent networking, digital science, digital
education and digital living environments. Most are closely tied to
Industrie 4.0.
To examine the priorities of the high-tech strategy and come up with
innovation recommendations, a working advisory group for innovation
policy was created.
Aditya
Industry 4.0 is often used interchangeably with the notion of the
fourth industrial revolution. It is characterized by, among others :
1 :- even more automation than in the third industrial revolution,
2 :-the bridging of the physical and digital world through cyber-physical
systems, enabled by Industrial IoT,
3 :- a shift from a central industrial control system to one where smart
products define the production steps,
4 :- closed-loop data models and control systems and
5 :- personalization/customization of products.
The goal is to enable autonomous decision-making processes, monitor
assets and processes in real-time, and enable equally real-time connected
value creation networks through early involvement of stakeholders, and
vertical and horizontal integration.

Kshitija
So we are firstly discuss about what is vertical and horizontal
integration???
1 :- vertical integration
vertical integration whereby all the systems in the traditional automation
pyramid are affected: from field level and control level to production
level, operations level and enterprise planning level.
Vertical integration will make the traditional automation pyramid view
disappear. The same goes for several systems and applications across
these various levels. Other systems such as ERP will dramatically
change while still others will be replaced by rapidly emerging
applications in the scope of Industrial IoT platforms, specifically
manufacturing platforms and vertical platforms for various tasks and use
cases in the many aspects of industry that get ever more features and
become combined in an interoperable ‘systems of systems’ approach and
by digital transformation platforms and business applications where IoT
platforms and functionalities get integrated into.

Nikita
2 :- Horizontal integration
Horizontal integration which is not about the hierarchical view of
several systems as in vertical integration but about the mentioned end-
to-end value chain: from supplier and the processes, information flows
and IT systems in the product development and production stage to
logistics, distribution and ultimately the customer.

Kazma

There are four design principles identified as integral to Industry

4.0:
1 :- Interconnection — the ability of machines, devices, sensors, and
people to connect and communicate with each other via the Internet of
things, or the internet of people (IoP)
2 :- Information transparency — the transparency afforded by Industry
4.0 technology provides operators with comprehensive information to
make decisions. 
3 :- Technical assistance — the technological facility of systems to assist
humans in decision-making and problem-solving, and the ability to help
humans with difficult or unsafe tasks
4 :- Decentralized decisions — the ability of cyber physical systems to
make decisions on their own and to perform their tasks as autonomously
as possible. 

Dipak

Industry 4.0 Application

The aerospace industry has sometimes been characterized as "too low
volume for extensive automation"; however, Industry 4.0 principles have
been investigated by several aerospace companies, and technologies
have been developed to improve productivity where the upfront cost of
automation cannot be justified. One example of this is the aerospace
parts manufacturer Meggitt PLC's project, M4.
The increasing use of the Industrial Internet of Things is referred to as
Industry 4.0 at Bosch, and generally in Germany. Applications include
machines that can predict failures and trigger maintenance processes
autonomously or self-organized coordination that react to unexpected
changes in production.
Industry 4.0 inspired Innovation 4.0, a move toward digitization for
academia and research and development.In 2017, the £81m Materials
Innovation Factory (MIF) at the University of Liverpool opened as a
center for computer aided materials science,where robotic
formulation,data capture and modeling are being integrated into
development practices.

Harshjit
Industry 4.0 and enabling technologies
Industry 4.0 is enabled by the technologies that integrate the digital and
real worlds. As an illustration, the core technologies related to
manufacturing systems and services, and supply chains, are as follows:
1 :- Big Data Analytics and Business Intelligence
Nowadays enterprises are embraced by huge amount of data from all
kinds of sources. All decisions, either operational or managerial, have to
rely on data analytics. All businesses cannot afford to ignore the data
and data analytics. It has been proven that the data are very useful and
much valuable when it comes to optimize production quality and
services, reduce energy consumption, and improve efficiency in
manufacturing. For example, data can be collected from various stages
of the manufacturing process. The large amount of data can be analyzed
in correlation with each other in order to identify the stages with
redundant processes that need be streamlined. The data can be turned
into actionable insights through early warning algorithms, predictive
models, decision support, workflows and dashboards. In fact, the data
have become the most valuable asset of an organization today. The data
analytics is the essence to a success of enterprises and their businesses.
Swati
2 :- Internet of Things (IoT).
Embedded computing and networking connect sensors and devices. The
Internet of Things connects more and more systems, devices, sensors,
assets and people through networks ranging from wireless, low-power
wide-area networks to wired high-capacity networks.
3 :- Cloud Computing
Many small enterprises cannot afford to own the storage for an
increasing amount of data. Some of them lack the analytical and
computational capabilities of processing the huge amount of data.
However, the data and the capabilities of analytics and computation are
even more important to them. Cloud service providers are offering a
growing opportunity to small enterprises through data storage and data
processing with affordable costs.

Rahul
4 :- Cyber-Security
Industrial systems are becoming increasingly vulnerable to threats as
there are various devices and large amount of data sets. The cyber-
security has to be put in place, which can recognize new vulnerabilities
and challenges, and ensure industrial systems and businesses free of
attacks.
Ashutosh
5 :- Autonomous Robots
The use of robots in manufacturing is no longer new. In Industry 4.0,
robots are self-sufficient, autonomous, and interactive, which are no
longer simply tools used by humans, but are the integral work units.

Priya
6 :- Additive manufacturing
Additive manufacturing, in particular, 3D printing enables
manufacturers to dramatically reduce the design time and cost, and
increase the variety and customization of products. The benefits and
values brought by additive manufacturing are even more evident in the
high mix low volume (HMLV) manufacturing.

Aditya
7 :- Augmented Reality
Customers are now more and more demanding. Businesses have to
provide customers all round services, from personalized product design,
dedicated manufacturing process to individualized after-sales services.
Augmented reality based systems are able to assist enterprises to gain
their competitive edges and win more business opportunities in such a
competitive marketplace.
Kshitija
Factories, products, customers and businesses in the environment of
Industry 4.0
Industry 4.0 uses digital technologies to make manufacturing more agile,
flexible and responsive to customers. It is able to create a smart factory
where the Internet, wireless sensors, software and other advanced
technologies work together to optimize the manufacturing system and
improve customer satisfaction. Industry 4.0 enables a business to react
more rapidly to market changes, offer more personalized products and
increase operational efficiency in a cycle of continuous improvement.

Nikita
1 :- Factories
With Industry 4.0, not only all manufacturing facilities in a factory, such
as sensors, actuators, machines, robots, conveyors, etc., are connected
and exchange information automatically, but also the factory becomes
conscious and intelligent enough to predict and maintain its operational
performance, to control its production process, and to manage its
manufacturing operations. Such a factory with Industry 4.0 is known as
a smart factory.

Kazma
2 :- Products
With Industry 4.0, a product is embedded with sensors, identifiable
components, and processors which can carry information and knowledge
to convey the functional guidance to the customers,
and transmit the users’ feedback to the manufacturing system. More
importantly, it allows the manufacturer to monitor the product
performance and provide information to customers, such as when and
which parts need to be replaced, and generate more revenue by shifting
to a product-as-a-service business model. Such a product with Industry
4.0 is named as a smart product.

Dipak
3 :- Customers
Industry 4.0 provides customers a new purchase means with a lot of
advantages just like customers could change their orders and ideas at any
time during production even at the last minute with no extra charge. The
he benefit from the smart products enables the customer not only to
know the production information of the product but also to receive the
advice of utilization depending on their own behaviors.

Harshjeet
4 :- Businesses
With Industry 4.0, there is a complete communication network existing
among various entities such as suppliers, factories, customers, products,
logistics, resources, etc. Every entity optimizes its configuration in real-
time, based on its demand and state in the network so as to maximize the
profit for all the entities with the limited sharing resources, and at the
same time, to reduce the costs and pollution, raw materials, CO2
emissions, etc

Swati
Industry 4.0: technologies, security, people/workers and society
It is important to note that Industry 4.0 is not just about those
technologies. It also looks at the impact on and role of society and
workers. Moreover, Industry 4.0 also has a strong focus on security. This
does not just mean security of data and communication networks, data
protection, cybersecurity in the broadest sense and industrial control
systems security (ICS security) but also the protection and security of
workers, industrial assets, critical infrastructure and ‘physical security’.
As industrial assets and critical infrastructure (from critical power
buildings to energy grids and more) get connected and attacks are on the
rise in the traditionally rather isolated industrial environments the stakes
and dangers of vulnerabilities and attacks are huge in industry 4.0 which
requires an end-to-end ‘security by design’ approach. Since attacks
increase and the consequences can be high it’s also recommended to not
just focus on cybersecurity but to combine this with risk management,
business continuity and other fields in what’s also known as cyber
resilience and becomes a must as keep transforming.

Rahul
Industry 4.0 and the fourth industrial revolution (4IR)
As a classic view of these four industrial revolutions, as Industry 4.0
became increasingly popular, was:

1 :- The first industrial revolution which REALLY was a revolution,

and, among others thanks to invention of steam machines, the usage of
water and steam power and all sorts of other machines
2 :- The second industrial revolution is typically seen as the period
where electricity and new manufacturing ‘inventions’ which it enabled.

Ashutosh
3 :- The third industrial revolution had everything to do with the rise
of computers, computer networks, the rise of robotics in manufacturing,
connectivity and obviously the birth of the Internet, that big game
changer.

Priya
4 :- the fourth industrial revolution we move from ‘just’ the Internet
and the client-server model to ubiquitous mobility, the bridging of
digital and physical environments (in manufacturing referred to as Cyber
Physical Systems), the convergence of IT and OT, and all the previously
mentioned technologies (Internet of Things, Big Data, cloud, etc.) with
additional accelerators such as advanced robotics and AI/cognitive
which enable Industry 4.0.

Aditya
Industry 4.0 challenges and risks
Some challenges faced during the revolution of industry 4.0 are as
follows :-
1 :- Economic
High economic costs
Business model adaptation
Unclear economic benefits/excessive investment
2 :- Social
Privacy concerns
Surveillance and distrust
General reluctance to change by stakeholders
Threat of redundancy of the corporate IT department
Loss of many jobs to automatic processes and IT-controlled processes,
especially for blue collar workers.
Increased risk of gender inequalities in professions with job roles most
susceptible to replacement with AI.

Kshitija
3 :- Political
Lack of regulation, standards and forms of certifications
Unclear legal issues and data security [51][52]
4 :- Organizational
IT security issues, which are greatly aggravated by the inherent need to
open up those[clarification needed] previously closed production shops
Reliability and stability needed for critical machine-to-machine
communication (M2M), including very short and stable latency times
Need to maintain the integrity of production processes
Need to avoid any IT snags, as those would cause expensive production
outages
Need to protect industrial know-how (contained also in the control files
for the industrial automation gear).

Nikita
Lack of adequate skill-sets to expedite the transition # And also there are
some following points which define some challenges towards a fourth
industrial revolution
1. The definition of a strategy (for Industry 4.0), challenge number one.
2. The rethinking of the organization and processes to maximize
outcomes.
3. Understanding the business case.
4. Conducting successful pilots.
5. Making the organization realize action is needed.
6. Change management, so often overlooked.
7. Company culture.
8. A true interconnection of departments.
9. Talent….

Kazma
Like these challenges there are several others, practical,
technological and ecosystem-related:

1. The challenges regarding the integration of IT and OT.

2. Data compliance questions.
3. Managing risk and lowering costs in uncertain times.
4. Dealing with the complexity of the connected supply chain.
5. A better understanding of IT and OT technologies and, more
importantly, how they can be leveraged.
6. Altering customer and industrial partner demands.
7. Competition and the fact that Industry 4.0 champions gain a
competitive benefit fast.
8. The eternal and extremely important human challenge

Dipak
The Industry 4.0 holistic strategy challenge
There is a big gap between those companies that have a long-term
strategy and the rest. On the other hand, it needs to be said that those so-
called ‘lighthouses’ are often active in the industry. The truth is that
most organizations don’t have an Industry 4.0 strategy and also suffer
from strategic short-termism. This isn’t even that surprising since, as
some brand strategists have been shouting for quite some years now
organizations overall are focusing far too much on the short term for
reasons that are partially related to the Zeitgeist and our real-time here
and now obsessions. Changing demands play a role as well as do
financial and competitive reasons.
Anyway, in the scope of Industry 4.0, it’s clear that ad hoc and siloed
initiatives, by far the large majority of initiatives, won’t cut it unless
they’re part of a strategic journey. And quite often they are not, leading
to fewer results than hoped or even failure.
Harshjeet
INDUSTRY 4.0 BENEFITS
We have mentioned some risks and challenges earlier but let’s look a bit
closer at some of the main advantages.
1 :- Enhanced productivity through optimization and automation
It’s also one of the first goals of Industry 4.0 projects. In other words:
saving costs, increasing profitability, reducing waste, automating to
prevent errors and delays, speeding up production to work more in real-
time and in function of the overall value chain, where speed is crucial
for everyone, digitizing paper-based flows, being able to intervene faster
in case of production issues and so forth.Industry 4.0 offers various
solutions to optimize, from optimized asset utilization and smoother
production processes to better logistics and inventory management.

2 :- Better quality products: real-time monitoring, IoT-enabled quality

improvement and cobots
If you have everything in your production system and its broader
environment hooked up with sensors, software, IoT technologies,
systems of insight AND the customer, you can also enhance quality of
your products. Automation definitely plays a big role here and so do the
typical components of cyber-physical systems (more below) and the
Internet of Things whereby quality aspects can be monitored in real-time
and robots reduce errors.

3 :- Better working conditions and sustainability

Improving working conditions based on real-time temperature, humidity
and other data in the plant or warehouse, quick detection and enhanced
protection in case of incidents, detection of presence of gasses, radiation
and so forth, better communication and collaboration possibilities, a
focus on ergonomics, clean air and clean factory initiatives

4 :- The development of innovative capabilities and new revenue models

You can transform processes, specific functions, customer service,
experiences and skillsets but in the end true value is generated by
tapping into new, often information-intensive, revenue sources and
ecosystems, enabling innovative capabilities, for instance in deploying
an as-a-service-capacity for customers, advanced maintenance services
and so on.

Swati
Better working conditions and sustainability
Improving working conditions based on real-time temperature, humidity
and other data in the plant or warehouse, quick detection and enhanced
protection in case of incidents, detection of presence of gasses, radiation
and so forth, better communication and collaboration possibilities, a
focus on ergonomics, clean air and clean factory initiatives (certainly in
Industry 4.0 as the EU wants to be leading in clean air and clean
anything technologies), the list goes on.

Aditya
Conclusion