CoEP - Mfg Automation

Data Focused View

of Industry 4.0
Atul Marathe
Professor of Practice
amm.mfg@coep.ac.in
05/20/2023 1
THE 4TH INDUSTRIAL REVOLUTION?

The fourth Industrial Revolution - 6 min (Siemens)

4th
Cyber-physical
systems

3rd
Automated production
By basic robotics, IT

Level of complexity
and electronics
2nd
Mass production by
electrical energy

1st
Mechanical
production powered
by water and steam
End of the Beginning of the Beginning Today
18th 20th century of the 70s
century
2 05/20/202
 Accelerating pace of changes !

05/20/2023 4
Traditional view of Industry 4.0

Advanced Simulation
Cyber Robotics
security System
Integration

Functional
Cloud
computing
Applications Additive
Manufacturing

Big Data
Augmented
Analytics
IoT platform Reality

Industry 4.0: My Course Section - YouTube

05/20/2023
Business Applications

1980
ERP, SCM, CRM PLM etc

Digitalize

IoT and IIoT for

1995
Data capture and Control
Digitize
(See - Think - Do)?
Industry 4.0 implementation

Analytics and AI based

2010

decisions

Data Intelligence
Data Focused View of Industry 4.0

6
Focus is on Reducing Four Latencies -

Events auto AI , ML and data AR / VR based Mostly auto actions

recorded Analytics used to Prescriptive Decisions Manual exception
Automatic
and get required data for action handling
networked

Events auto Network to share MIS reports and Auto actions for some
Semi recorded Context relevant data Predictions Based Routine decisions else
Automatic
locally as required decision manual action

Events Computer MIS and status Manual Action

Manual noted Applications Reports based
provide insight decisions

Action
Decision Latency
Latency
Data Aggregation
Latency

Event Insight
Latency
 Industry 4.0 – Data Focus
Application
Data & Past
Cloud Computing
Trends

External data
Static/ Stream Manual
Simulations
decisions
Edge Computing
Predictive
analytics
Control Actions
For machine
Prescriptive
execution
Recommendations
Machines
Digitize – Data Capture / Action

Cloud Computing

Action data
Summary data From Data Intelligence …
For business apps

Edge Computing Edge Computing

Closed loop
corrective actions
Data at
Source

Machines
Machines
 Digitization Aspects
Ability to capture data created at source, mostly machines on the shop floor or
other points where any event can be tracked digitally and recorded for any
immediate closed loop action or to be shared with other applications on need
basis.

Ability to use digital data from IoT applications leading to machine action

• Personalized order capture with visualization *

• Design and Engineering data capture [Unit 5, 6]
• Production data Capture [Unit 1, 4]
• Machine health status data capture [Unit 3]
• Material movement data capture [Unit 2]
• Quality test results data capture [Unit 5]
• Manual decisions / IoT data sourced decisions to execute actions *
• (* Not in syllabus yet !)
 Digitalize – Data for Decision Making

Cloud Computing

Real time
machine data Business Apps Data
summary
Integration
ERP
SCM External data
Edge Computing
CRM Static/ Stream
MES etc

Manual data capture

In business apps

Industry 4.0 happening in India - 4 min (Bosch)

 Digitalization aspects
Ability to store and integrate digital data received from various devices on
machines or otherwise, and from computer applications, when any event gets
triggered.

Rule based generation of triggers, alerts warnings for manual action and/or IoT
based machine action.

Analyzing historical data trends and external data for

improvements and prediction of any preemptive actions to be taken

• Supply Chain Management (SCM)

• Enterprise Resource Planning (ERP)
• Product Life Management (PLM)
• Manufacturing Execution System (MES)
• Customer Relationship Management (CRM)
Data Intelligence – Decision making
Trends and
Application
Data
Cloud Computing
External
data
Static/ Manual
Stream Simulations
decisions
Current data summary
Predictive
analytics
Control Actions
For machine
Prescriptive
execution
Recommendations
Machines
 Data Intelligence Aspects

Ability to leverage digitization as well as digitalization to create closed loop

systems that take action based on internal and external data available .

Less human interaction is most preferred for real time action based on data
based decisions.

• Historical Data driven analytics for prediction and prescription

• Real time external static and streaming data included
(Nowcasting) for data driven decisions like -
– Customer journeys, life term value
– Sentiment analysis based service / support
– Loyalty programs
• Robotic Process Automation (RPA)
• Digital Twins using Augmented / Virtual reality (AR/VR)
techniques
• Self Learning systems (ML / AI based)
3 data pillars to manage 4 latencies
Application
Data & Past
Cloud Computing
Trends

External data
Static/ Stream Manual
Simulations
decisions
Edge Computing
Predictive
analytics
Control Actions
For machine
Prescriptive
execution
Recommendations
Machines
 Objective is to Reduce Four Latencies -

Action
Decision Latency
Latency
Data Aggregation
Latency
Event Insight
Latency

Focus Areas to reduce latency are –

o Capture Data by IoT

o Collate relevant data by ERP, RPA (Data Acquisition)
o Conclude based on data AI/ML
o Control digitally (IoT, AR)
 Data Focus - Current Challenges
o Most companies have some ERP systems and some have IoT enabled data capture

o IoT data is at best integrated with robotics for automated applications using edge
computing applications

o IoT data is not well integrated with ERP , SCM and other business applications
o Most of the data required for applications is manually entered or at best captured by
mobiles, RFID readers or optical scanners

o Very few companies use any decision systems that are automated using AI / ML
applications. Most of them are experimenting or in pilot modes

o AR / VR are rarely used for factory work simulation. They are more used for
marketing and product presentations with canned demos and for training at times

o Digital factory is still a distant dream for many !

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 So what next?
First get familiar with some of the basic pillars or Industry 4.0
• “On demand learning” model is most suitable
• Try to be a ‘Jack of All’ or ‘Master of ONE’

Today, we will now discuss the vision of Industry 4.0 level implementation

Digital Twins

It lays down a clear vision of how a fully automated factory that

is completely Industry 4.0 compliant, will look like in the future.
Required software is available today to create digital twins of a
factory, if it really works that way, or plans to do so !

05/20/2023 18
 1. Digital Twins

Why Digital Twins? 3 min (Seimens)

MS Azure - Digital Twin platform (12 min)

Digital Twin Simple and detailed – IBM ( 8 min)

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 Digital Twin - definition
• Digital twin refers to a digital replica of
physical assets (physical twin), processes,
people, places, systems and devices that can
be used for various purposes.
• The digital representation provides both the
elements and the dynamics of how an
Internet of Things device operates and lives
throughout its life cycle.

05/20/2023 20
 Data aspects of Digital Twins
• Device Data collection
– Collection of data around IoT devices used
• IoT setup and data interfaces
• Better Data Analysis
– Cognitive Computing on data generated
• Big data, Business Analytics
• Better Operations
– Dynamic Re-calibration based on insights
• As designed vs actual results
• Changes to ripple through all stages

05/20/2023 21
 Digitalized Processes – Interconnected

Design: The sooner you know how to visualize them, the better you can make them later

Planning: Design and Manufacturing work together - hand in hand

Layout: Product Design and its production layout are better synchronized for efficiency

05/20/2023 22
 Digitalized Processes – Interconnected

Validation: Simulate to ensure process details are right and flow is smooth
Throughput optimization: Issues are bound to come so improve effectiveness, utilization
Execution: Production performs as you planned it with changes cascading through stages

GE - Mind + Machines in action (15 min)

05/20/2023 23
 Metaverse Project – any takers?
Scope: The team will explore various alternate Metaverse platforms available and
critically compare for its use for Enterprise Digital Twins.
Build a prototype and test the feasibility with sample data.

Technologies Tools/ Platforms

• AR/VR/XR/MR • Unreal Engine:

(Augmented, Virtual, Extended, • https://www.unrealengine.com/en-US

Mixed reality)
• Unity 3D: https://unity.com/
• Graphics/ Animation
• Audio/ Video/ Movie
• Playcanvas:
• Digital Twin
• https://playcanvas.com/explore
• Chatbot
• Avatar/ Galaxy • Chaarmi Worlds Inc. https://chaarmi.com/

• Meta (Facebook): https://about.meta.com/

05/20/2023 24
 Standing offer from C4i4

Machine to Machine connectivity demo

at CoEP for
Small and Medium scale
manufacturers around Pune,
Invited by Center for Industry 4.0 (C4i4)
RTP - SPPU campus

05/20/2023 25
 atulmarathe@outlook.com

© Acknowledgements: C4i4 Pune (Samarth Udyog)

05/20/2023 26