Title :- Industry 4.

0
Student number - 32078896
Student Name – Anusha Yerra
Module – Industrial Automation
Lecturer – Salah Talamali
Table of Contents
1. Aim:-....................................................................................................................... 3
2.Objectives :-............................................................................................................3
3.Introduction:-..........................................................................................................3
4. Overview of Industry 4.0 topologies :-................................................................4
4.1.Industry 4.0 :-.....................................................................................................4
4.2. Revolution of Industry 4.0 :-..............................................................................4
4.3 .Industry 4.0 topologies :-..................................................................................4
4.4. Overview of SCADA (Supervisory control and data acquisition) :-...................5
4.4.1 SCADA Components :-...............................................................................6
4.4.2 Fundamental features of SCADA :-.............................................................6
4.4.3 SCADA in the context of Industry 4.0 :-......................................................7
4.4.4 Applications of SCADA system in industry 4.0 :-........................................7
4.5. Overview of DCS (Distributed control systems )...............................................8
4.5.1.DCS Components :-....................................................................................8
4.5.2.Fundamental features of DCS :-.................................................................9
4.5.3.Applications of DCS system in industry 4.0 :-.............................................9
5.Application 1(Manufacturing) :-..........................................................................10
5.1.Manufacturing in industry 4.0 :-.......................................................................10
5.2.Associated Smart Manufacturing technologies................................................11
5.2.1 Virtual Reality............................................................................................11
5.2.1 Cyber- Physical systems...........................................................................12
5.2.3 Big data Analytics..................................................................................... 12
5.2.4 IoT and IIoT...............................................................................................12
5.2.5 Artificial intelligence's................................................................................12
5.3 Future developments.......................................................................................12
6.Application 2(Healthcare 4.0) :-...........................................................................13
6.1.Manufacturing in industry 4.0 :-.......................................................................13
6.1.1 Health Care 1.0 to Health Care 4.0 Transition :-.......................................13
6.2 Global healthcare disruption caused by COVID-19 :-......................................13
6.3. Important Industry 4.0 technologies that could aid in COVID 19 breakouts. . .13
6.3.1. Artificial intelligence..................................................................................13
6.3.2 Internet of Things......................................................................................14
 6.3.3. Big Data................................................................................................... 14
6.3.4 3D Scanning............................................................................................. 14
6.4 Future scope....................................................................................................14
7.Example (Smart watch):-.....................................................................................15
7.1 Smart watch :-................................................................................................. 15
7.2 The Advancement of the Smart Watch............................................................15
7.3 Use in Health monitoring:-...............................................................................15
7.4 Used for tracking:-..........................................................................................16
7.5 Costing:-.......................................................................................................... 16
7.6 Why it is industry 4.0 and not industry 3.0 ?....................................................16
8.Summary :-........................................................................................................... 16
1. Aim:-
The purpose of the comprehensive research is to present an in-depth analysis of
Industry 4.0, including an introduction to its two main applications, Manufacturing
and Healthcare 4.0 , as well as an investigation of how Industry 4.0 topologies are
applied in both contexts. We'll look at the importance of smartwatches, which have
integrated seamlessly into people's daily lives.

2.Objectives :-
(A) To provide an in-depth review of Industry 4.0, examining its significance and
important applications in the manufacturing and healthcare industries.

(B) To research the different topologies and technologies related to Industry 4.0,
such as augmented reality, cloud computing, robots, big data, and cyber-physical
systems (CPS).

(C) to investigate the idea of distributed control systems (DCS) and supervisory
control and data acquisition (SCADA) in critical infrastructure sectors, focusing on
their significance and security implications.

(D) We'll use the smartwatch to illustrate how consumer technology has evolved
while also examining its pricing, industry 4.0 applicability, and health-tracking
features.

3.Introduction:-
The technology in charge of supervising and controlling massive production systems
is referred to as distributed control systems (DCS) and supervisory control and data
acquisition (SCADA). These systems are essential for key infrastructure sectors like
pipelines, chemical plants, petrochemical facilities, pipelines, dams, electric power
production, and transportation. In a networked and digitally-driven world, the security
of DCS and SCADA systems has become a matter of extreme concern given that
these industries are crucial for society.

The term SCADA describes the centralized systems in charge of industrial

infrastructures. Although the terms "SCADA," "process control," and "ICS" are
frequently used interchangeably, the difference may reside in the observation that
SCADA systems are believed to facilitate coordination of infrastructures rather than
exercising control over the discrete elements of these infrastructures.

A distributed controller system (DCS) is one in which each separate subsystem and
component is controlled by one or more controllers rather than being centralized (as
in SCADA). Together, SCADA and DCS provide a complete toolkit for enhancing
operations, maintaining security, and reaching previously unheard-of levels of
efficiency (Macaulay, 2011).
4. Overview of Industry 4.0 topologies :-

4.1.Industry 4.0 :-

"Industry 4.0" refers to the fourth industrial revolution's present period, which
emphasizes connectivity, automation, machine learning, and real-time data. Industry
4.0, also referred to as IIoT or smart manufacturing, combines physical
manufacturing and processes with intelligent digital technologies, machine learning,
artificial intelligence, and big data to create a more complete and well-connected
ecosystem for businesses that concentrate on manufacturing and supply chain
management (Guo, 2021).

The manufacturing revolution known as "Industry 4.0" is now centred on increasing

productivity and resource efficiency. It introduces "smart manufacturing," which
enables mass customisation and flexible production through IoT and cyber-physical
systems. Part of the German programme known as Industry 4.0 is this change
(Jamwal, 2021).

4.2. Revolution of Industry 4.0 :-

The industrial revolutions have produced notable advancements and serve as

examples for how our daily lives might be improved. There have been four significant
industrial revolutions throughout history that served as the foundation. As indicated
in Fig. 1, these revolutions (Baygin, 2016).

Figure 1. The Four Phases of Industrial Revolution (Adebayo, 2019).

4.3 .Industry 4.0 topologies :-

Industry 4.0 topologies include some of the following.

1. cyber-physical systems.
2. The Internet of things.

3. Cloud computing.

4. Robotics.

5. Big data

6. Argumented reality

Figure 2. Industry 4.0 topologies (shu black board).

4.4. Overview of SCADA (Supervisory control and data acquisition) :-

A collection of software programmes used to control industrial operations is known

as SCADA, or supervisory control and data acquisition. In order to monitor
equipment and environmental conditions, real-time data collection from far-off sites is
necessary (elprocus).
 Figure 3. General SCADA Network (elprocus)

4.4.1 SCADA Components :-

The hardware components of a SCADA system are "Remote Terminal Units (RTU),"
"Master Terminal Units (MTU)," sensors, and actuators. A SCADA system is a
composite of these hardware components and software applications. The "Human
Machine Interface (HMI)," a central database called the "Historian," and other user-
specific software tools are all included in its software (Yadav, 2019).

The hardware elements gather and send data to field controller systems, which
subsequently relay this information to other systems in charge of processing and
quickly displaying it on a human-machine interface (HMI). Furthermore, SCADA
systems keep thorough records of every occurrence for the purpose of reporting
process status and locating issues. Additionally, SCADA programmes provide
alarms to notify when circumstances might become unsafe (Yadav, 2019).

Figure 4. Architecture and Block Diagram of SCADA system (pinterest).

4.4.2 Fundamental features of SCADA :-

While some SCADA systems may have unique features designed for particular
sectors or needs, most of these systems include the following capabilities:

1. Data Collection: A crucial component of SCADA systems is data gathering.

Information is gathered by sensors and then sent to field controllers. The data is then
transmitted to the SCADA computers by these controllers.

2. Supervisory Control :SCADA allows users to monitor and manage industrial

operations remotely from a single place..

3. The SCADA system includes both real-time and historical data, giving users the
ability to compare present performance to historical trends.

4. Alarms alert SCADA operators to potentially important circumstances that may

exist in the system. These alerts can be configured to notify operators of system
failures, process obstacles, or the requirement for modifications, halts, or starts in
various SCADA activities.

5. Reports produced by SCADA system operations include a wide range of topics,

including system status, process effectiveness, and customized reports made to
meet particular needs (Gaushell, 1987) (tech target).

4.4.3 SCADA in the context of Industry 4.0 :-

Real-time Analytics: SCADA incorporates real-time analytics, transforming data

into insights that can be used for proactive maintenance, anomaly detection, and
continuing process optimization, reducing downtime and increasing productivity.

Cybersecurity: As part of Industry 4.0, SCADA systems put strong security

measures in place to combat increased connectivity-related risks, protecting crucial
systems from potential cyberthreats and preserving system integrity.

Inter-connectivity: SCADA systems connect to a wide range of sensors, devices,

and Io T-capable components, enabling seamless data transfer between
manufacturing buildings. The Industrial Internet of Things (IIoT) is supported by this
connectivity, which allows for immediate data sharing and analysis (PECB).

4.4.4 Applications of SCADA system in industry 4.0 :-

Manufacturing: SCADA monitors and controls manufacturing lines to ensure

smooth workflow, preserve quality standards, and maximize resource efficiency.
 Figure 5. Manufacturing(bb)

Energy: SCADA controls renewable energy sources, grid stability, and power
production

Figure 6:- Energy 4.0

Agriculture:SCADA supports precision agriculture by regulating irrigation, soil, and

greenhouses.

Figure 7.Agriculture 4.0

4.5. Overview of DCS (Distributed control systems )

A distributed control system, also known as a DCS, is an automated control system

for processes or plants that includes several distributed control loops and
autonomous controllers dispersed across the system (Plant automation technology,
n.d.).

4.5.1.DCS Components :-
Diverse components with various roles inside the system make up a distributed
control system. These elements work together effectively to enable efficient
supervision and control of industrial processes. Controllers, input/output (I/O)
modules, communication networks, and human-machine interfaces (HMI) are a
DCS's main components (.wevolver, n.d.).

Figure 8. Architecture of DCS(Black board shu).

4.5.2.Fundamental features of DCS :-

Decentralized Control: Multiple controllers are given control duties by DCS,

allowing for more localized decision-making.

Redundancy: To maintain strong system availability and dependability, DCS usually

incorporates redundancy.

Advanced Process Regulation: To precisely control process variables, DCS uses

complex algorithms.

Integration: DCS combines various control loops within a network with ease.

Scalability: DCS systems are flexible and can grow in accordance with the
complexity of a process (.wevolver, n.d.).

4.5.3.Applications of DCS system in industry 4.0 :-

1. Process industries
Figure 9. Industry 4.0 in process industry (black board shu).

2. Power generation and distribution

Figure 10. Power generation (iiot-world, n.d.)

3. Water and waste treatment (.wevolver, n.d.)

5.Application 1(Manufacturing) :-

5.1.Manufacturing in industry 4.0 :-

A new generation of manufacturing systems, known as hybrid systems, is the result

of Industry 4.0. In order to achieve Industry 4.0, hybrid systems consider
redesigning/configuring machines by combining machines with sensors, actuators,
and control architectures.

In terms of process modifications and technological advancements intended to cut

down on production lead times and inefficiencies, the relationship between lean
manufacturing and Industry 4.0 was investigated and condensed. As a result, lean
manufacturing is strongly advocated as a practical and long-lasting production
process that makes Industry 4.0 adoption easier (Garbie, 2020).
The term "smart manufacturing" refers to the use of interconnected machinery and
tools to increase manufacturing productivity while also optimizing energy use and
workforce allocation. This is done by incorporating technologies like big data
processing, artificial intelligence, advanced robotics, and seamless connectivity
between these components (Phuyal, 2020).

Figure 11.A Schematic of smart manufacturing components (Phuyal, 2020).

5.2.Associated Smart Manufacturing technologies

Diverse technologies related to manufacturing, computation, virtualization,

communication, and data management are combined in smart manufacturing. Due to
the interaction of these technologies, the scope of smart manufacturing technologies
has grown, resulting in cost-efficiency, time preservation, simplified setup, increased
understanding, quick market response, adaptability, and remote oversight (Phuyal,
2020).
Figure 12. components of smart manufacturing (Phuyal, 2020).

5.2.1 Virtual Reality

Through computer-generated simulations, virtual reality (VR) provides experiences

that are as real as possible. Wearable VR gadgets that include video, audio, and
GPS simulate physical presence. VR facilitates digital design testing for modification,
lowers the cost of prototypes, and helps manufacturing training (Phuyal, 2020).

5.2.1 Cyber- Physical systems

Cloud computing enables remote monitoring of industrial operations over the

internet, enabling control from any place. Cyber-Physical Systems (CPS) use
internet-based data processing to combine digital activities with the physical
environment. Sensors and actuators serve as the physical components of cloud-
based SCADA, while software and internet connectivity make up the cyber layer.
The civil infrastructure, automotive, transportation, and aerospace industries all use
CPS (Phuyal, 2020).

5.2.3 Big data Analytics

Smart manufacturing is enabled through data collection and analysis from various
sources (production, customer feedback, demands). Manufacturers modify their
products based on user feedback. Big data improves marketing and predictive
manufacturing by helping to spot problems and forecast consumer behaviour
(Phuyal, 2020).

5.2.4 IoT and IIoT

Home, transportation, healthcare, and other areas employ IoT, but IIoT focuses on
industrial applications, connecting physical objects like sensors and processes via
the internet. Interaction is made possible by the IIoT for client presentations, process
control, maintenance, and production planning (Phuyal, 2020).

5.2.5 Artificial intelligence's

Artificial intelligence promotes human-robot collaboration, lowers risk in dangerous

environments, and enhances maintenance and failure detection in production. It
permits independent judgement, production optimization, machine changes, and

prompt warnings (Phuyal, 2020).

5.3 Future developments

Immersive VR training will be added to smart manufacturing in Industry 4.0 to speed

up skill acquisition. Processes will be optimised by AI-driven automation, real-time
control will be made possible by sophisticated CPS, and data analysis will be
improved by a larger IIoT network. Making decisions will be aided by predictive big
data analytics. The new era of Industry 4.0 will begin as a result of these advances,
which will improve productivity, responsiveness, and quality (Phuyal, 2020).

6.Application 2(Healthcare 4.0) :-

6.1.Manufacturing in industry 4.0 :-

4.0 in healthcare refers to the fourth industrial revolution, which is represented by the
principles of Industry 4.0. The core idea behind Health 4.0 is the use of intelligent
robots that can make judgement on their own without human interaction because
they have access to massive databases.

It offers a new and creative viewpoint for the healthcare industry and covers a wide
range of options for utilizing Industry 4.0 innovations to improve healthcare. The
objective is to provide patients with improved, more useful, and cost-effective
healthcare services while also boosting the sector's efficiency and productivity
(healthcare- digital, n.d.)

6.1.1 Health Care 1.0 to Health Care 4.0 Transition :-

Numerous characteristics between industrial and health care systems are shared.
The provision of health care has gone through several revolutions and changes over
the years, much like manufacturing or other industries.

Figure 13.History of health care evolution 1.0 to 4.0 for health care (Li, 2021)

6.2 Global healthcare disruption caused by COVID-19 :-

The COVID 19 (Coronavirus) pandemic has had a substantial impact on the

healthcare infrastructure and treatment systems in practically every country (Javaid,
2020).The COVID-19 epidemic has accelerated the need for a way to deliver
medical care remotely while preserving the calibre and accuracy of diagnosis and
treatment options. Here is where telehealth is useful (Li, 2021).

6.3. Important Industry 4.0 technologies that could aid in COVID 19 breakouts
Industry 4.0 innovations can pinpoint COVID-19 signs, clearing up any confusion
about the illness and even predicting the likelihood of developing it. They aid in
tracking possible health problems and determining the propensity for recovery
(Javaid, 2020).

6.3.1. Artificial intelligence

AI has the power to predict and manage viral epidemics, challenge false information
about COVID-19 on social media, optimize drug and vaccination trials, build robots
that clean up after themselves, carry out online medical exams, and provide crucial
CT scans for the early detection of pneumonia. This technology provides numerous
advantages while assisting in the production of important medical equipment (Javaid,
2020).

Figure 14.AI applications in the war against COVID-19 (Paul, 2021).

6.3.2 Internet of Things

IoT is extremely helpful in the COVID-19 conflict. Drones assist epidemiologists in

locating patient zero and tracing contacts, track quarantine violators, assure
quarantine compliance, and remotely monitor patients at home, all while monitoring
quarantine and mask enforcement and identifying disease sources (Javaid, 2020).

6.3.3. Big Data

Big data is essential for analysing and forecasting the transmission and effects of
COVID-19. Trackers collect worldwide data in real-time to help researchers,
clinicians, epidemiologists, and decision-makers fight the infection (Javaid, 2020).

6.3.4 3D Scanning
A con-tactless technique called 3D scanning helps detect COVID-19 in the thoracic
cavity and quantify the virus. It also has uses in robotic mapping, virtual reality,
motion capture, and industrial design (Javaid, 2020).

6.4 Future scope

For pandemic reactions like COVID-19, Industry 4.0 will eventually retain vital
healthcare data, impacting treatment modalities and expediting medical procedures.
For improved healthcare systems, the healthcare sector must integrate digital
technologies, necessitating software and equipment changes. In order to counter the
effects of viruses like COVID-19, this revolution brings disruptive innovation (Javaid,
2020).

7.Example (Smart watch):-

7.1 Smart watch :-

A little gadget meant to be worn on the wrist is a smartwatch. Similar to

smartphones, these gadgets have touchscreens, interactive games, and the capacity
to track several health parameters like heart rate. A smartwatch is essentially a
watch that has been improved with additional connectivity and software functions
that go beyond the standard characteristics of conventional watches.

A smartwatch (SW) is a daily wearable with smartphone-like features that resembles

a traditional wristwatch. SW s provide calls, weather updates, messaging, GPS,
fitness data, and more. They also provide internet connectivity. They manage apps
like smartphones do and have touchscreens. They contain LCD or OLED displays
and sensors on the inside, which are run by rechargeable lithium-ion batteries. They
have features like cameras, accelerometer, heart rate monitors, and GPS on the
outside (Chandel, 2022).

7.2 The Advancement of the Smart Watch

Digital watches were a status symbol in the 1990s since they were first quite pricey.
Their difficult production contributed to their high price. However, application-specific
integrated circuits (ASICs), which are more readily available and simpler, have
replaced the initially intricate circuitry of digital timepieces.

Due to improved sensors and sophisticated, energy-efficient Bluetooth or Wi-Fi

chips, wearable devices like wristbands (like Fitbit) and watches (like Pebble) have
gained popularity. They link up with gadgets that track data on exercise and health
(Tan 2016).

7.3 Use in Health monitoring:-

Heart rate is a popular subject. Many individuals utilise portable devices, particularly
smartwatches linked to smartphones, to gather data. Instead of big phone brands,
user-made smartwatches are currently more common. Heart rate information is in
high demand since it can be used to anticipate everyday activities in people. The
systematic process of acquiring and analysing data to answer research questions
and validate hypotheses is known as data collection (Wijaya, 2014)

7.4 Used for tracking:-

The use of GPS and GSM through IoT by smartwatches improves security. To help
keep ladies secure, they pair with phones via Bluetooth to deliver contacts and law
enforcement emergency notifications. Because of its portability and technological
capabilities, smartwatches are becoming more and more popular because they
provide convenience and are an affordable option (Helen)

7.5 Costing:-

Costs for smartwatches vary widely depending on the brand, the watch's features,
and the model. Particularly for premium or specialized editions, they may start at 50
pounds and go up to 2000 or more. Because of new product introductions and
technological developments, prices may change.

7.6 Why it is industry 4.0 and not industry 3.0 ?

Smartwatches are referred to as "industry 4.0," not "industry 3.0." Smartwatches, a

symbol of the fourth revolution, offer a variety of functions, are accessible, and
demonstrate technical advancement in contrast to fundamental timekeeping in the
third revolution.

8.Summary :-
IoT, cyber-physical systems, big data, and AI are just a few of the topologies that
make up Industry 4.0, which has the potential to boost productivity and satisfy
consumer needs in the manufacturing sector. Smartwatches are also becoming
more used in daily life for activities like heart rate monitoring, GPS tracking, and
remaining connected without a smartphone. Additionally, it talks about how COVID-
19 will affect healthcare and how Industry 4.0 technologies can help with pandemic
response.
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