Analysis and Management

of Production System
Lesson 16: Introduction to Industry 4.0

Prof. Giulia Bruno

Department of Management and

Production Engineering

giulia.bruno@polito.it
Industrial revolutions in the history

4th revolution
3rd revolution Automation of
manufacturing using
Introduction of nuclear modern smart
2nd revolution energy. Rise of technology. Large-scale
electronincs (trannsistor M2M communication and
Increase steel
1st revolution production, and microprocessor), IoT are integrated for
telecommunication and increased automation,
introduction of electric
The first industrial computers. This is the communication and self-
power and use of
revolution led to iron era of high-level monitoring, and
petroleum. Inventions
coal and steam automation thanks to two production of smart
of cars, airplanes,
technology, the major inventions: PLCs machines that can
electric-powered
expansion of railroads (Programmable Logic analyze and diagnose
trolleyes and subway
and the mass Controllers) and robots. issues without the need
trains.
production of textiles. for human intervention.

1750-1850 1850-1914 1969-1990 today

Enabling technologies
Internet of Things

IoT
IoT

The Internet of Things (IoT) is a system of interrelated computing

devices, mechanical and digital machines, objects, animals or
people that are provided with unique identifiers and the ability to
transfer data over a network without requiring human-to-human
or human-to-computer interaction.
IoT

Sensors
and actuators
Interaction with the
environment Data processing
Analyze and gain insights from data

User interface
Show data to the end-
user and allow him to
interact
Connectivity
Data flow between the environment and the internet
IoT
IoT
Cloud

Cloud

IoT
Cloud

Cloud computing is a model for enabling ubiquitous, convenient, on-

demand network access to a shared pool of configurable computing
resources that can be rapidly provisioned and released with minimal
management effort or service provider interaction.*
In other word…

*“The NIST Definition of Cloud Computing”, Special Publication 800-145,

U.S. Department of Commerce
Cloud

The delivery of computing services (servers, storage, databases,

networking, software and more) over the Internet (“the cloud”).
Cloud
Cloud – Why?

● IT staff cost saving ● Hardware cost saving

Companies become less dependent on Companies can reduce their capital
on-site IT professionals for expenditures by only pay for the
troubleshooting. computing services that they need (pay
as you go).
● Scalability/Flexibility
Companies can expand and decrease ● Reliability
their computing capabilities at any time Services using multiple redundant sites
depending on their needs. can support business continuity and
disaster recovery.
● Mobile Accessible
Mobile workers have increased ● Maintenance
productivity due to systems accessible in Cloud service providers do the system
an infrastructure available from Maintenance.
anywhere.
Vertical-horizontal integration

Cloud

IoT
H-V
integrati
on
Vertical-horizontal integration

Horizontal integration refers to the integration of different

information systems that are used in the phases of production
planning and business processes*.

Vertical integration means integration of information systems at

different hierarchical levels, all in order to exchange information
from the bottom to the top of the hierarchy and vice versa*.
Horizontal integration
Vertical integration
Vertical-horizontal integration

Creation of
Ecosystem-wide
data information
between various
systems and
across all
processes to
provide more
knowledge,
insights and value
creating actions
Additive manufacturing

Cloud

IoT

H-V
integration

AM
 Additive manufacturing

It is the manufacturing process to build up 3D objects by adding

layer-upon-layer of material.
Additive manufacturing - Why?

● No additive tooling is needed

● Design freedom
● Complexity for free
● Economical One-of-a-Kind Production (OKP)
● Possibility to reduce waste
● Potential for simpler supply chains, shorter lead times and lower
inventories
● Part optimization: no design restriction means parts can be
made lighter and stronger
● Part consolidation and elimination of production steps
Data analysis

Cloud
Data
IoT analysis

H-V
integration
AM
Data analysis – DIKW pyramid

DIKW acronym comes from the initial letters

of the elements that make up the pyramid,
starting from the bottom to the top.
Data analysis – DIKW pyramid

Wisdom is the ability to increase effectiveness. Wisdom adds value, which

requires the mental function that we call judgement.
E.g., if the temperature is very high, it is better to drink a glass of water every
two hours

Knowledge component of DIKW is defined with reference to information

having been processed, organized or structured in some way.
E.g., in March in Turin the temperature generally does not exceed 27°C

Information is the knowledge by description, and it is

differentiated from data in that it is useful. It is also defined as
data that are endowed with meaning and purpose.
E.g., Mario is 176 cm tall, this box is 12 kg, in Turin it is 32°C today

Data is conceived of as symbols or signs,

representing stimuli or signals, that can be usable
or not. They are in the famous Data Lake in which
usability depends on the skill of the fisherman
E.g., 5, 8.6, 9/3, 8.6 cm, 25 px, 9°C, 25-07-1987
Data analysis

Data analysis is a
process of
inspecting,
cleaning,
transforming and
modeling data
with the goal of
discovering
knowledge of the
problem that
supports the
decision-making
Data analysis – Big Data
Data analysis

● Mathematical and statistical techniques

 they do not need big data
 how they work is clear and their knowledge is open
 often they are complicated
● Methods based on artificial intelligence, machine learning
 bigger data means greater performances
 they are a black box
● Visualization and graphical method and tools
 they do not process data
 they transform data in a readable object
Data analysis
Data analysis
Collaborative robots

Cloud
Data
IoT analysis

Collaborative H-V
robots integration

AM
Cobots

A robot is a re-programmable multifunctional manipulator designed

to move materials, parts, tools, or specialized devices, through
variable programmed motions for the performance of a variety of
tasks*.
 Cobots

Autonomous and
collaborating robots that are
integrated with numerous
sensors and standardized
interfaces and are designed
to work together with
humans in the same physical
environment
Cobots
Cobots

Easy to program Fast to setup Flexible Safe

Tools to make Traditional robots Cobots don’t require a They don’t need
programming require weeks, lot of space and they safety cages, they
accessible to have an
advanced robots can be simply
everyone environmental
require hours redeployed cognition
Cobots
Cobots
 Simulation

Simulation
Cloud
Data
IoT analysis
Collaborative
robots
H-V
integration

AM
Simulation

“The process of designing a model of a real system and

conducting experiments with this model for the purpose either of
understanding the behavior of the system or of evaluating
various strategies (within the limits imposed by a criterion or set
of criteria) for the operation of the system.”

In other words…
 Simulation

Create a tool to do many test

Simulation – Why?

● Have flexibility
● Manipulate time
● Improve understanding of system
● Answer “what-if” questions
● Model large and complex systems
● Study problems with less danger and lower costs
● Study new designs without interrupting real system
● Study new designs without needing extra resources
Simulation
 Augmented reality

Augmented
reality

Simulation
Cloud
Data
IoT analysis
Collaborative
robots
H-V
integration

AM
Augmented reality

Augmented Reality (AR) is the perception of digital information-

usually visual perception-synchronized with objects and places in
the physical world around the user. [IEEE]

In other words…
Augmented reality

A set of technologies
that add digital images
on the real world
Augmented and Virtual Reality

Real
environment

Augmented
reality

Augmented
virtuality

Virtual
environment
Augmented reality in I4.0

• VISUALIZE
• INSTRUCT AND GUIDE
• INTERACT
Augmented reality in I4.0

• VISUALIZE
AR can reveal features or
systems that would be
difficult to see with the naked
eye
Augmented reality in I4.0

• VISUALIZE
• INSTRUCT AND GUIDE
AR can replace hard-to-
understand 2-D instructions,
such as those for a repair
process in a manual, with
interactive 3-D holograms
that walk the user through
each step
Augmented reality in I4.0

• VISUALIZE
• INSTRUCT AND GUIDE
• INTERACT
AR can replace physical
controls such as buttons,
knobs and built-in
touchscreens with virtual
ones that are visually
superimposed on the target
 Cyber security

Augmente
d reality
Cyber
security Simulatio
n
Cloud
Data
IoT analysis
Collaborativ
e robots H-V
integration

AM
 Cyber security

Protection of computer
systems and networks
from attacks to their
hardware, software or
data.
Cyber security

● Cyber security standards are security standards which

enable organizations to practice safe security techniques
to minimize the number of successful cyber security
attacks
● Cyber security refers to the technologies and processes
designed to protect computers, networks and data from
unauthorized access, vulnerabilities and attacks delivered
via the Internet by cyber criminals
● Though, cyber security is important for network, data and
application security
Cyber security
All these technologies
(particularly IoT) increase
dramatically what the experts
call the surface attack, that is
the opportunities to launch
malicious and devastating
attacks by cyber criminals.
All connected means more
doors and windows
If not properly designed,
information systems and
especially products are used
as "ports" from which to
launch attacks on others.
You pay in damages, image
and market share
 Sustainability

Augmented
reality
Cyber
security
Simulation
Cloud
Data
IoT analysis
Collaborative
robots
H-V
integration

AM
Sustainability

A sustainable approach to business management guarantees

business benefits from various points of view:

● Social sustainability as a guarantee and respect for internal

and external stakeholders (workers, suppliers, customers,
investors, etc.). It has a positive impact on how much they trust
the company.

● Environmental sustainability as a choice for low-impact

practices on the environment, has a positive impact on costs.
The efficiency of processes, as well as the adoption of energy
efficiency measures, are able to lead to important monetary
savings.
An Industry 4.0 application

IoT and Data Analytics for Predictive Maintenance

What is maintenance?

Maintenance is the set of activities that

have the objective of maintaining an
element, machine or system, in a state
in which it can perform its function.

MONITORING DECISION ACTION

Degradation of performance

The performances degradation of an object is due to the

degradation of the material or components of the object.
It is function of age and/or usage and it is influenced by opening
environment.
The desired performances are a central point during the designing
and building/manufacturing of every engineered object.
Cost of maintenance

DIRECT COSTS
These costs are incurred due to maintenance and repair actions.
Often, these are the costs which may be tracked down easily in
account books.

INDIRECT COSTS
These are the costs resulting from the consequences associated
with failure or unplanned maintenance actions. The indirect costs
are, in general, higher than the direct costs and depend on the
engineered object. They are also difficult to measure.
Maintenance management

Maintenance management deals with maintenance‐related

decision making at the strategic, tactical, and operational levels,
and then initiating actions to implement the decisions.
 Maintenance strategies
MAINTENANCE

EMERGENCY Performed after a general emergency of the plant.

UNPLANNED

BREAKDOWN2 Intervention only when the failure occurs.

Performed
AUTONOMOUS by the operator himself.

Performed only while

SHUTDOWN the system is not in use.

PREVENTIVE
Performed regularly,
PERIODIC according a planning.

PLANNED Performed after the estimation of

PREDICTIVE the system condition and time to
failure.

Revisions aimed to improving the value of a system,

PROACTIVE
as opposed to all other corrective maintenance.
Predictive maintenance

● Maintenance strategy that tries to predict when a piece of

equipment might fail so that maintenance work can be
performed just before that happens
 predictions are based on the condition of the equipment that is
evaluated based on the data gathered through the use of
various condition monitoring sensors and techniques
● This approach promises cost savings over routine or time-
based preventive maintenance, because tasks are
performed only when warranted
● The global predictive maintenance market will expand at a
CAGR (Compound Annual Growth Rate) of 37.9% to 2025,
at which time it is expected to be valued at $28.24 billion
Predictive maintenance

Increasing research topic during the years Pubblications in geographic areas

Evolution of technologies Pubblication trend of ML applications for PM

CNC machine

● CNC machine are programmable

● The program contains all necessary
information to machine the part:
 Geometrical
 Technological
● The program is read, interpreted and
automatically executed by the MCU

Milling video:
https://www.youtube.com/watch?v=UuOo
wWWh460
Tool condition monitoring

Condition Monitoring is the process of monitoring one or

more parameters of machine to predict its potential faults early

• Tool Condition Monitoring: monitoring the tool status to

predict its wear

• Condition Based Maintenance is done through the

analysis of the equipment status to decide when apply
maintenance operations

• Remaining Useful Life (RUL) is the estimation of the time

before the failure of an equipment
Tool wear and RUL

Flank wear
VB

For the Flank wear of milling tools

(cemented carbides, high-speed
steels and ceramics), the ISO 8688-
1:1989 defines a level for the failure
condition (𝑉𝐵𝑚𝑎𝑥 = 0.6𝑚𝑚)
Aim of the application

Definition of a framework to predict the wear of the

tools and based on it to estimate the RUL of the
tools and allow the planning of maintenance
activities
Process parameters

Parameters set before the execution of the manufacturing process

CUTTING
SPINDLE SPEED
SPEED

FEED RATE

MATERIAL
DEPTH Hardness
OF Toughness
CUT
Wear resistance
Sensor measures

Parameters that describe physical effects generated by the

manufacturing activity
Preprocessing

FEATURE GENERATION
Feature generation is the
process of transforming raw data
into meaningful features.
Time domain Frequency domain
 Data analysis

Training dataset
(12 cases)
Predictive algorithm
Train – Test split
selection Performance
Testing dataset measures
(3 cases)
Web application implementation