UNIT I SESSION 2

NEED OF I4.0
1. It helps manufacturers with current challenges by becoming more flexible and
making reacting to changes in the market easier
2. It can increase the speed of innovation and is very consumer centered, leading to
faster design processes.
3. Workers can become coordinators at the center of production, possibly improving
the work-life balance of employees
4. Leads to an innovation economy
5. Puts the consumer in the center of all activities
6. Even puts humans into the center of production
7. .
Will enable sustainable prosperity
8. Increase productivity
9. Create new product and business models
10. Leading into a sustainable and profitable future
 connectivity in I4.0
It is 2:00 am, and the machine in Europe is down. The planner accesses the system and
finds out that products have to be shipped in the morning. He immediately sees open
capacities and a stock of raw material in his factory in the US and triggers a start of
production there. Back in Europe, a maintenance technician is informed and he sees
immediately machine process data in his office and can locate the problem to a workstation.
On the shop floor, from his tablet, the technician accesses the workstation and begins
modifying the data-acquisition time for the process data. In minutes, he recognizes and
solves the. problem. The machine is back up and running again.
 connectivity in I4.0
Smart factories require the underlying processes and materials to be connected to generate
the data necessary to make real-time decisions.

In a truly smart factory, assets are fitted with smart sensors so systems can continuously pull
data sets from both new and traditional sources, ensuring data are constantly updated and
reflect current conditions.

Integration of data from operations and business systems, as well as from suppliers and
customers, enables a holistic view of upstream and downstream supply chain processes,
driving greater overall supply network efficiency.
 connectivity in I4.0
Smart devices: Determining which components will enable data creation, starting with smart
relays over additional sensors and connectors that function as smart devices, by collecting –
for example – information about energy consumption or monitoring condition.

Physical connectivity: Positioning more smart devices inside a machine creates additional
connections, which generates more data to be transferred and at the same time, reduces the
size and cost of nodes; this leads to the need for alternative connectivity solutions including
wave-guided data transfer and wireless solutions.

Connecting the content: Managing a data path for added value data; the connectivity
solution will need to manage, aggregate, buffer, and process data as well as open up a
secure path to transmit data to the enterprise-level IT system.
 Factors to choose right IoT connectivity
1. Range: The distances over which communication between the various devices in an IoT network
takes place.
2. Bandwidth: The volume of data that’s transferred in a given time period.
3. Interoperability: The ability of a connected device, app or sensor to communicate with another,
usually from a different manufacturer or host.
4. Data Rate: The rate at which data can be transmitted over a network, measured in Kbps or Mbps.
5. Security: Measures taken so that data is protected during the various stages of transmission, as
well as during storage.
6. Power consumption: The power consumed by a device when data transmission takes place.
7. Scalability: The ability of a protocol to continue to perform as the network grows in number of
connected devices.
 Types of connectivity
1.Wired
A.Serial bus
B.USB
C.Ethernet

2. Wireless
Shortrange
A.Near Field (NFC)
Needs both devices within field to communicate
›Contactless payments (apple pay, android pay, paypal etc)
›Ticket validations (Oyster)
›File sharing
›Multiplayer gaming
B. Bluetooth
Transmission at the ISM band
Low transmission power
Low penetration properties (walls, doors, windows etc)
 Types of connectivity
C. WiFi
Transmission at the ISM band
Low transmission power
Very good penetration properties (walls, doors, windows etc)
High transmission rate
Highest availability

D. Cellular (2G, 3G, 4G)

E. LPWA - Low Power Wide Area
F. Licensed spectrum (NB-IoT)
G. Unlicensed spectrum (Sigfox, LoRa, etc.)
H. Satellite
connectivity in I4.0
 Nine Technologies in I4.0
1. BIG DATA ANALYTICS ; In an Industry 4.0 context, the collection and comprehensive
evaluation of data from many different sources—production equipment and systems as well
as enterprise- and customer-management systems—will become standard to support real-
time decision making.

2. AUTONOMOUS ROBOTS ; Robots will eventually interact with one another and work
safely side by side with humans and learn from them. These robots will cost less and have a
greater range of capabilities than those used in manufacturing today..

3. SIMULATION : Simulations will be 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.
 Nine Technologies in I4.0
4. SYSTEM INTEGRATION ; With Industry 4.0, companies, departments, functions, and
capabilities will become much more cohesive, as cross-company, universal data-integration
networks evolve and enable truly automated value chains.

5. THE 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 will also decentralize analytics and decision making, enabling real-
time responses.

.
6. CYBERSECURITY : With the increased connectivity and use of standard communications
protocols that come with Industry 4.0, the need to protect critical industrial systems and
manufacturing lines from cybersecurity threats increases dramatically. As a result, secure,
reliable communications as well as sophisticated identity and access management of
machines and users are essential.
 Nine Technologies in I4.0
7. THE CLOUD ; More production-related undertakings will require increased 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

8. ADDITIVE MANUFACTURING ; Companies have just begun to adopt 

additive manufacturing, such as 3-D printing, which they use mostly to prototype and produce
individual components. With Industry 4.0, these additive-manufacturing methods will be widely
used to produce small batches of customized products that offer construction advantages,
such as complex, lightweight designs.
.
9. AUGMENTED REALITY : Augmented-reality-based systems support a variety of services,
such as selecting parts in a warehouse and sending repair instructions over mobile devices.
These systems are currently in their infancy, but in the future, companies will make much
broader use of augmented reality to provide workers with real-time information to improve
decision making and work procedures.
Thank You
VINOTH KUMAR H