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Industry 4.0 ,Nine Pillars

Submitted by:

Atulya Bhardwaj (20374)

Ekansh Daniel (20378)

Vishwa Pratap singh (20425)

Mrinal das (20395)

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Introduction

Industry 4.0 refers to a new phase in the Industrial Revolution that focuses heavily
on interconnectivity, automation, machine learning, and real-time data. Industry 4.0,
also sometimes referred to as IOT or smart manufacturing, marries physical
production and operations with smart digital technology, machine learning, and big
data to create a more holistic and better connected ecosystem for companies that
focus on manufacturing and supply chain management. While every company and
organization operating today is different, they all face a common challenge—the
need for connectedness and access to real-time insights across processes, partners,
products, and people.
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Big Data and Data analytics

Data analytics, once an IT application is now penetrating into manufacturing and

supply chain industry. Power of data analytics and pattern recognition can be
harnessed in the manufacturing industry to reduce downtime and wastages.
In our facility, data can be collected at different levels of manufacturing process. If a
PCB or a batch of PCBs is found to be faulty, their manufacturing data can then be
retrieved and comprehensively evaluated to arrive at a pattern. Process involving
those patterns can be redesigned and re-evaluated to reduce wastage and increase
productivity.
Predictive maintenance can be carried out based on the data collected. This is cost-
efficient and safer than the conventional routine maintenance method.
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Simulation

Complex algorithms and testing them allows for projects like inner-city intelligent
parking or a ‘Dead reckoning’ capability for GPS denied environments to come to
fruition.
Consider that in our manufacturing facility, we have three robots to solder the PCBs.
With this in mind, our sales team promises the clients that their order will be
delivered in 3 weeks. Unfortunately, one of the older robots faces some technical
glitch with deadline in 10 days. Simulations with different speed of work can be
operated to arrive at an optimum speed at which the robots can operate without
frying themselves up and meet the deadline.
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Horizontal and Vertical Integration

Horizontal integration takes networking among the cyber-physical systems and

enterprise systems to an unprecedented level. Every device and system at the same
level of manufacturing in the same facility or the other is connected with each other.
As this enables communication between systems in different facilities, jobs can be
planned and adjusted by the machines themselves. Downtime at a facility can be
compensated by overtime at another facility with no human intervention whatsoever
Vertical integration makes it even better. Every system and humans at all hierarchy
has all the data with required abstraction
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Industrial Internet of Things

You would have heard about the concept of IOT, I bet. An ecosystem in which all
the sensors and actuators with the ability to function separately and communicate
with every other element is called IOT. Industrial IOT is the same but with increased
ruggedness to survive the harsh environments of the industry.
Consider that our factory has run out of solder. There is no point in pushing out
batches of printing circuit boards when there is no solder lead available to integrate
the components. Instead of a human stopping the process, solder lead holder
enabled with sensors could prompt the inventory team to buy more solder in prior. If
the inventory team had failed to refill, the printer (etcher) can be turned off or can
go in idle mode after receiving a signal from the solder holder.
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Autonomous Robots

Autonomous robots transfer raw materials, half-finished and completed

goods in an easier, faster and smarter way. They operate based on a complex
logic algorithm, meaning they don’t require any preset path to carry out their
duties.
These robots catalyze the manufacturing process. The amount of time that
can be gained and latency that can be cut down is equal to the amount of time
taken to program controlled robots. Unlike the conveyor belt, it is portable
and its duty can be varied.
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The Cloud

Cloud is a remote system that can be accessed provided from anywhere using
the internet. There are a lot of cloud services available today of which notable
are IaaS, PaaS, SaaS. Communication among machines themselves and
between machines and humans are hugely backed by cloud services.
Amazon.com Inc. is the best example. A consumer gets updated about the
whereabouts of his order in real time. This is not a one-to-one message. Once
your package has arrived at the warehouse, information is updated in cloud
which is then notified to you. Every time you check for your package’s
present location, get query is executed in real time to let you know about your
package.
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Cyber Security in Industry 4.0

Cyber security becomes the talk of the town since the dawn of Information
technology. The greatest nightmare of any information technology firm is having
their server and data hacked. Preventing such a catastrophe and safeguarding the
data and performance of the server is the sole purpose of cybersecurity.
Very fancy and futuristic. But how is it going to affect a small firm that produces
Printed Circuit Boards?
As more and more components get connected and one device’s action is based on
the output of another device, more operational decisions are decentralized, more
security concerns are raised.
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Augmented Reality

Augmented Reality based systems are storming the technology industry. Few years
ago they found their applications only in flight simulators. Today remote repair
instructions can be sent to literally any part of the earth with internet accessibility. It
helps technicians to enhance their skills by practicing high end repairs and
maintenance over and over again using augmented reality.
Consider for example, we have an equipment worth of some million dollars needing
some form of maintenance. Before carrying out the job on the actual equipment, a
training session can be conducted. Once the technician is confident enough to be
impeccable, he can do the same with the actual equipment. It is a win-win situation.
We don’t lose our equipment; Technician does not get embarrassed messing up the
job.
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Printing

Companies are already using additive manufacturing techniques like 3D-printing to

make prototypes and Proof of concepts. The flexibility of Industry 4.0 allows us to
design complex designs which are nearly impossible with conventional
manufacturing processes.
Most of the conventional manufacturing processes are subtractive manufacturing
which includes wastage of raw materials. Additive manufacturing drastically
reduces if not totally eliminate the wastage of raw materials.
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