Accialini Training & Consulting provides support in Industry 4.0. Please visit our website www.accialiniconsulting.com or send us an email at info@accialiniconsulting.com for additional info. Please don't forget to subscribe to our newsletter!

1. Accialini Training & Consulting
Senior Consultant
Industry 4.0
Walk Through
Nicola Accialini

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About
• Industry 4.0 implies the utilization of different technology
trends, mainly digital, to offer solutions to future challenges
such as higher productivity ad efficiency, better and faster
decision making, mass personalization of new products,
higher transparency and lower cost.
• The concept of Industry 4.0 appeared for the first time in
an article published in November 2011 by the German
government that resulted from an initiative regarding high-
tech strategy for 2020.

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The Objectives
• Seize Industry 4.0 opportunities to develop a Smart
Factory
• Reduce production costs by using I4.0 technologies
• Increase product quality by introducing error
proofing technologies, more repeatable processes,
therefore more reliable products
• Increase product customization opportunities
without increasing costs

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The Opportunity
• Modernize / Digitalize factories without
massive investments
• Use low cost technologies which provide
high benefits in return
• Create a state-of-the-art factory by
changing point of view

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The Solution
• Provide an overview of what Industry 4.0
means, it impacts on factories,
challenges and opportunities
• Visit your shop floor to identify hidden
opportunities to exploit I4.0 technologies
to improve processes without a huge
investment;
• Create a final report in which
opportunities are listed, including
potential benefits, challenges and costs

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Our Proposal
Simulation 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;
The Internet of things (IoT) is the network of physical devices, vehicles,
home appliances, and other items embedded with electronics, software,
sensors, actuators, and connectivity which enables these things to
connect, collect and exchange data.
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.

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Our Proposal
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
Horizontal and Vertical 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.
Big Data Analytics (BDA): a big amount of data can be collected with
digitalization of products and services. This amount of data can be
analyzed to predict the market trends, to improve a manufacturing
process, to assess supply chain performance

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Our Proposal
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.
Cloud computing: 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.
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.

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Why ATC
• ATC has collected 10+ years of experience in developing high-
quality critical modules in the aerospace industry, more
specifically accessory and power gearboxes for aeroengines,
probably the most critical parts of an airplane.
• In the last few years most of my activities were focused on
developing a brand-new assembly facility, based in Germany,
for critical engine module, which is setting new standards in
the aeroengine industry.
• This implies a large use of aforementioned technologies: in
fact, the only way to stay competitive in high wage countries is
to introduce smart technologies to reduce overall production
costs, improve product quality, and deliver on time.

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The Approach
• Our execution strategy incorporates proven methodologies,
extremely qualified personnel, and a highly responsive
approach to managing deliverables.
• Our execution strategy aims primarily to provide the
organization the right tips to use Industry 4.0 technologies
based on past experience and massive research in the field.
• Following is a description of our project methods, including
how the project will be developed, a proposed timeline of
events, and reasons for why we suggest developing the
project as described.

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Introduction to Industry 4.0
• This gives a preliminary overview on what Industry 4.0
means, it includes an explanation on what the 9 key
technologies are, main benefits, impacts and main
challenges to face with.
• It normally takes 4h in a training room, but this can be
done on-line few days before the meeting as well.

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On-site Walk Through
• The on-site walk through consists in the visit your shop
floor.
• Depending on the size, the walk through can take from
half a day up to 3 days.
• More in detail, the I4.0 walk through starts from your
warehouse, where to raw material is stored, and
continues throughout your manufacturing process,
including machining processes, intermediate inspection,
special processes, final inspection, final assembly and the
delivery store.

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Identify I4.0 opportunities
• Scope of the walk through is to identify hidden opportunities that
currently lay behind your production system.
• Indeed, although some of you are probably aware about the basic
application of most I4.0 technologies, it is sometimes difficult to imagine
the big potential that these technologies have in your shop floor.
• Therefore, to identify such opportunities, it is important that ATC
personnel is escorted through the shop floor by competent and skilled
employees, and
• ATC personnel should let be free to talk with workers to
understand their needs and explain the impact of potential solution;
• ATC personnel should let be free to take pictures, unless strictly
forbidden for security or IP reasons. In this sense, we strongly
recommend to sight a non-disclosure agreement before the walk
through;

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Preliminary Recommendations
• At the end of the walk through, we will be able to provide you
your “Industry 4.0 index”, plus some easy-to-implement
recommendations and discuss the way forward.
• The Industry 4.0 index (I4.0i)is the result of a package of 30
simple questions, which gives you an idea of the level of
implementation of I4.0 technologies in your factory and an
estimation of potential improvements:
• I4.0i < 10%: Very Low
• 10 < I4.0i < 30%: Low
• 30 < I4.0i < 60%: Medium
• 60 < I4.0i < 80% High
• I4.0i > 80%: Very High

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Final Report
• A detailed report will be prepared at the end of the Walk
Through, which includes new potential technologies to
implement, cost estimations, benefits and further
recommendations.
• This will take approximately 2 weeks from the visit,
depending on the size of the shop floor.

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Benefits
• Financial
• Lower production costs
• Technical
• Increase productivity
• Foster the mass personalization
• Better product quality
• Other
• Improvement of employee’s performances
• Reduce employee turnover
• Improve employee’s satisfaction and morale
• Enhance company reputation and profile

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Request a Quotation
• # People to train:_________
• Company name:______________________________
• Please send a copy of this page to the following email:
nicola@accialiniconsulting.com
• If interested, please submit these few information and help
us to tailor the service to fit best to your needs:
• Introduction to Industry 4.0: In which form would you like
to have this service?
• I4.0 Walk Through: How long should it last?
□Virtual Class □Face to face□Online (free)
□2 days □3 days□1 day □more (specify):_____