1.
Integrated Industry
MANUFACTURING OF THE
FUTURE
JAYESH C S PAI

2.
Manufacturing’s next act
Astonishing rise in data volumes,
computational power, and connectivity,
especially new low-power wide-area networks
Emergence of analytics and business-
intelligence capabilities
New forms of human-machine interaction such
as touch interfaces and augmented-reality
systems
Improvements in transferring digital
instructions to the physical world, such as
advanced robotics and 3-D printing.

3.
INDUSTRIE 4.0
Connected Industry
Manufacturing facilities that share information
with work pieces and call a technician for help
if needed
Continuous data exchange between all
participating units – from the production robot
to inventory management to the microchip.
This connects all production and logistics
processes together, making the industry more
intelligent, efficient and sustainable.

4.
Digitalizing plants - Digital Factory
 Integrated engineering from planning to operation. Digital
Factory is a virtual image of the real production that shows the
production processes in a virtual environment.
 Process plants today are highly complex and have lifecycles of
many years. For this reason it is even more important to replace
cost-intensive physical tests and prototypes by simulation – from
virtual commissioning, simulation parallel to operation, through
to error identification and plant optimization. The repeated, and
thus error-prone entry of data already captured in a different
context, must be replaced by a consistent digital process chain.
Documents no longer need to be available in printed form.
Instead, updated plant descriptions and plant layouts should
always be available online.
 The benefit is clear: speedier and safer planning, parallel
engineering, faster commissioning, safer operation and updated
documentation.

5.
WHAT CAN WE EXPECT IN A COMPANY
IMPLEMENTING DIGITAL
PRODUCTION?
 The implementation of the digital business achieves
significant benefits:
 1 Cost savings through better use of resources of
30%,
 2 The cost savings achieved by optimizing material
flows 35%,
 3 Reduction of the number of machines, tools and
workplaces by 40%,
 4 Total manufacturing production growth of 15%,
 5 Reduce time to market for new products by 30%.

6.
The Web of Technologies
 The full digitization of a company’s operations,
integrated vertically (to include every function and the
entire hierarchy) and horizontally (linking the
suppliers, partners, and distributors in the value chain
and transferring data among them seamlessly).
 The redesign of products and services to be
embedded with custom-designed software, so that
they become responsive and interactive, tracking their
own activity and its results, along with the activity of
other products around them.
 Closer interaction with customers, enabled by
these new processes, products, and services.

7.
Integrated Energy
 Energy systems are digitally controlled and machines
exchange information with products - the era of
networked industry.
 Good use of energy not only means utilizing it more
efficiently, but also sensibly combining renewable
energy production and the right energy storage in an
integrated energy system.
 Hybrid smart grids such as photovoltaic systems on
rooftops, biogas plants, business-owned CHP plants
etc. ensure the efficient coordination of production,
storage, grid management and consumption so that
suppliers maintain a smooth system. New
measurement, control and regulation technologies
need to be integrated into the conventional grid to
make this possible.

8.
SMART MATERIALS & COATINGS
 The Future is light and easy
 Reducing energy and material consumption has
become necessary to stay competitive in nearly every
sector of industry.
 Materials having sensoring properties that turn them
into smart materials
 Nanotechnology coatings make smart materials out of
everyday things.
 New adhesives think for themselves
 3D printing revolutionizes manufacturing
 Surface coatings can fundamentally change the
properties of materials; they reduce wear, repel water
and impurities and even act as filters.

9.
SMART ADHESIVES
Fire-resistant sealants
Diaper adhesives that change color
when wet and send signals

10.
3D Printing Disrupting Global Mfg
 1. True Rapid Prototyping. Automation is making products that would need
a month to go through three or four design changes in the prototyping phase
now taking a week. Products are getting to market faster, and companies are
saving significant time and money.
 2. Rapid Design Iteration (A/B testing of physical products). Ford is 3D-
printing molds in four days at a cost of $4,000 instead of six months and
costing hundreds of thousands of dollars.
 3. Low volume production. With conventional manufacturing, a company
has to commit to creating tooling or molds before a single end use part can be
produced. With 3D printing, there are no set-up costs whatsoever.
 4. Mass Customization. Large quantities of an item are produced, each one
customized like your actual knee is scanned and a perfect replica is printed
and ready for you prior to surgery.
 5. Virtual Inventory. Inventories around the world will soon shrink
dramatically as holding inventory is very expensive. We make what we need,
when and where we need it.
 6. The Long Tail of Parts. Older but still-useful products don’t become
waste; their lifespan need not be pre-determined by scale production
limitations. We can print any part for as long as it is needed.
 7. Product Innovation Renaissance. Lower entry barriers and ability to
enable radically more complex and useful objects are initiating a new era of
product innovation.

11.
GE is using 3D metal printers to
produce fully redesigned new fuel
injection system for jet engines,
reducing components from 21 parts
to 1 and incorporating geometries
that are simply impossible to create
using any other manufacturing
method, resulting in astonishing
increases in efficiency.

12.
Lightweight design gives greater
flexibility in manufacturing
From vehicles to rotor blades, from construction to home
furnishings…the trend to “lightweighting”, necessitated
by the need for energy efficiency and environmental
protection, is now everywhere in our lives.
“In the automotive
sector, plastics are
evolving from non-
load-bearing
decorative
components to high-
strength functional
and structural
components that
require excellent
resistance to impact
and heat.”

13.
Large-scale Lightweight
Construction Initiative
 Steel offers significant scope for reducing raw
material and energy consumption, which is nowhere
near fully utilized yet.
 Possibilities for reducing weight and raw material
consumption for forged components have been
explored
 Savings could be found primarily in the drive train
and chassis: wheel hubs and injection system,
crankshaft, gears and other components.
 Redesign and development is not that simple in the
metal production and processing sector, with its high
division of labor.
 Casting simulation allows to reliably predict the
performance of a given component under operating
conditions

14.
Functionally Optimized
Construction
 Manufacturers are currently required to integrate the increasing number
of drive concepts and energy storage systems into vehicle structures.
 The vehicle bodies of tomorrow, particularly in view of alternative drive
systems in small series with lots of different versions, will not only need
to be lighter, but above all will also require a highly flexible design.
 The consequence is an increasing number of vehicle derivatives, which
demand adaptable bodywork concepts that are economical to
manufacture.

15.
Surface coatings that change
components' aerodynamic properties

16.
Predictive Maintenance

17.
MINIMIZING DOWNTIME
 Technology manufacturers are equipping machines
and industrial systems with sensors that enable
remote monitoring when combined with the right
software.
 Defective components that could soon lead to a
system shutdown are identified independently of the
usual maintenance schedule, and can be replaced
before damage actually occurs.
 Continuous data analysis gives users of smart
machines a much more precise picture of their
facilities: Operating errors or wrong settings become a
thing of the past in this scenario
 Predictive maintenance thus moves into predictive
producing – and a production unit becomes a veritable
smart factory.

18.
Predictive maintenance
 Industry 4.0 is about interconnectedness – the digital
integration of machines, products, components and
up- and downstream systems. With predictive
maintenance, sensors tap into this interconnectedness
to continuously capture in-service machinery condition
data, combine it with data from other systems, such
as ERP and CRM software, and analyze it.
 In this way, predictive maintenance detects the early
warning signs of outages and triggers the necessary
preventive measures.
 Predictive maintenance offers three main benefits:
improved production planning, greater machine
availability and a reduction in unscheduled plant
shutdowns.

19.
Cobot (Collaborative Robot)
 Designed to work alongside human workers,
assisting them with a variety of tasks.
 Co-bots are affordable, highly adaptable, and almost
plug-and-play
 As OEMs come under increasing pressure to increase
automation in order to satisfy extremely high-quality
expectations at the right price, collaboration between
robots and humans working side by side on the
production line can eliminate unwanted variabilities
without losing the human touch needed to complete
complex assembly tasks, individualize products
where needed, or deal with exceptional events.
 Collaborative robots can also assist operators in
space-constrained workplaces such as laboratories,
which can benefit from automating tasks such as
dispensing or loading/unloading but are unable to
accommodate the guarding needed for a
conventional robot.

20.
HOW COBOTS ARE DIFFERENT
FROM ROBOTS.
1. Partnering in human-machine
teams
2. Relief from risky activities
3. "Smart" and safe behavior
4. Flexible and teachable
5. Usable anywhere

21.
Integrated Energy
 Energy resources can be efficiently piloted using management
systems.
 Today’s energy planners must strive to balance many conflicting
factors. At the most basic level, they must seek to balance
energy needs (demand) and energy resources (supply) across
two dimensions:
 • Ensuring access to adequate, affordable and secure energy
services to satisfy human needs and achieve socioeconomic
development.
 • Promoting production and use of energy services in ways that
are consistent with the pursuit of sustainability.
 Systematic analysis of all the factors that influence the evolution
of energy systems. It facilitates problem solving and makes it
possible to explore linkages, evaluate trade-offs and compare
consequences, thereby helping countries to develop an effective
energy strategy that supports national sustainable development
goals.

22.
ENERGY CONCEPTS OF THE FUTURE
 Reducing energy consumption is more than a matter
of image. From energy recovery to autonomous
power stations, modern technologies are achieving
efficiency ratings, that also have a remarkable effect
on the bottom line.
 Efficiency is the ratio of cost to result. This common
economic principle certainly applies to energy
savings: If you can achieve the same or even a better
result at lower cost, your efficiency increases.

23.
 Learning energy efficiency networks
 Ten or fifteen companies from the same
sector or the same region meet regularly
to share knowledge around energy
savings, and take advantage of synergies.
Instead of each one having to research for
itself how to use their energy more
efficiently, their shared knowledge grows
exponentially for all.

24.
Energy efficiency
 Energy efficiency: Intelligently manage electricity and climate control!
 Use energy efficiently, identify and take advantage of potential savings,
reduce in-house costs – Integrated Energy makes all this possible.
 Energy Productivity - An energy-flexible factory is built on three pillars:
building technology including energy storage, production planning and
production control systems, and the machinery proper.
 Reduce its total emissions by 40 percent

25.
"Digital Energy"
 Legal obligations relating to energy audits, rising
costs and the prospect of tax concessions and
government grants are leading to increased interest in
energy management systems, especially in energy-
intensive sectors such as the pulp industry, steel and
food production, metalworking and earthworks.
 However, energy flows in manufacturing and
production and the associateinfrastructure can only be
optimized through effective acquisition and analysis of
the relevant data.
 This is where "Digital Energy" comes in. Energy
systems will be digitally controlled.

26.
The Digital Power Plant Pays
Dividends
 Customers are reaping the benefits of going digital in
greater power output, better fuel efficiency, reduced
emissions and an ability to meet market demands as
they change from day to day. Whether for a single
power plant or across a fleet, power companies are
mapping their transformation, beginning with
connecting and monitoring assets and moving to
leveraging insights for dispatch optimization.
 No matter the fuel: fossil, coal-fired steam or nuclear,
digital is transforming the way power plants are
managed toward improved productivity, safer and
more secured operations and greater profitability.

27.
Energized Future
 Reduce
Cut down on energy costs and consumption by
switching to energy-saving technology like LEDs.
 Produce
Become more energy independent by adopting on-site
generation like solar and combined heat and power.
 Shift
Use energy storage, electric vehicle charging and
demand response to reduce energy costs and carbon
footprints.
 Optimize
Harness data insights from the Industrial Internet to
improve performance, create efficiencies and plan for
the future.

28.
How to make it happen
 Solar Solutions
 Gain energy independence by generating lower-cost, renewable
solar energy on site.
 LED Lighting
 LEDs are an environmentally friendly lighting solution that deliver
huge long-term energy savings—and can be integrated with an
array of intelligent hardware.
 Energy Storage
 On-site energy storage offers reduction in demand charges and
helps protect factories and warehouses from grid vulnerabilities.
 Intelligent Endpoints
 Sensors, motion detectors, Wi-Fi-enabled monitoring, energy load
controls and more can be installed into LED fixtures or other
hardware to collect valuable data about your operation.

29.
Energy Efficiency Centre
 Main objectives of EEC are:
 Support to renewable energy and energy efficiency
utilization for sustainable development and as a
result improve national energy security level and
minimize negative environmental impact.
 Increase awareness of the civil society and the
country’s decision makers on the environmentally
friendly and economically sound ways of energy
production and consumption as well as on the
potential for renewable energy and energy efficiency.

30.
DECENTRALISED ENERGY
 Decentralised energy, as the name suggests, is
produced close to where it will be used, rather than at
a large plant elsewhere and sent through the national
grid.
 This local generation reduces transmission losses and
lowers carbon emissions. Security of supply is
increased nationally as customers don’t have to share
a supply or rely on relatively few, large and remote
power stations.
 There can be economic benefits too. Long term
decentralised energy can offer more competitive prices
than traditional energy. While initial installation costs
may be higher, a special decentralised energy tariff
creates more stable pricing.

31.
Trigeneration
 Production of electricity, heat and cooling
in one process

32.
Motion, Drive & Automation
 One consequence of Industry 4.0 is that power transmission and
fluid power products (Antifriction bearings, gearboxes, pumps,
cylinders and valves, linear motion systems) are now sources of
big data
 Manufacturers of power transmission and fluid power technologies
integrate mechatronic and CPS (cyber-physical systems) modules
which are key enablers of efficient, intelligent Industry 4.0
production processes.
 By incorporating digital connectivity, these modules facilitate
integration across the control and production layers, thereby
helping to pave the way for a new era in manufacturing
characterized by intelligent, self-optimizing and autonomous
processes.
 Predictive maintenance detects the early warning signs of outages
and triggers the necessary preventive measures.

33.
Cloud-based manufacturing Capturing and applying company-wide intelligence and knowledge
through the use of analytics, business intelligence (BI), and rules
engines.
 Piloting and then moving quickly to full launch of supplier portals and
collaboration platforms, complete with quality management
dashboards and workflows.
 Designing in services is now becoming commonplace, making cloud
integration expertise critical for manufacturers.
 Accelerating new product development and introduction (NPDI)
strategies to attain time-to-market objectives.
 Managing indirect and direct channel sales from a single cloud
platform tracking sales results against quota at the individual, group
and divisional level is now commonplace across all manufacturers
visited.
 Using cloud-based marketing automation applications to plan, execute
and most important, track results of every campaign.
 Automating customer service, support and common order status
inquiries online, integrating these systems to distributed order
management, pricing, and content management platforms.
 Increasing reliance on two-tier ERP strategies to gain greater
efficiencies in material planning, supplier management and reduce
logistics costs.
 Reliance on cloud-based Human Resource Management (HRM)
systems to unify all manufacturing locations globally.

34.
Research and innovation
 Today’s ideas are tomorrow’s innovations.
Exchanging knowledge for the products of
tomorrow.
 Because it brings together supply and demand in the
market of ideas.
 Scarce resources must be used ever more efficiently.
Product cycles are becoming shorter. Customers want
increasingly individualised products. As a result,
industrial production is becoming more dynamic. The
flexibility and complexity of production systems is
increasing. This is linked to a fundamental need for
research and development
 Adaptronics, Bionics, Organic Electronics, Textile
Solutions, Energy and Mobility Research, Nano and
Microtechnology

35.
Bio-economy
 Bioeconomy comprises those parts of the economy that
use renewable biological resources from land and sea –
such as crops, forests, fish, animals and micro-
organisms – to produce food, materials and energy. The
overarching goal is to reduce dependence on petroleum
and other fossil fuels.

36.
Organic Electronics
 There are good economic and ecological arguments in
favour of using organic materials in light fittings,
photovoltaic collectors, printed circuit boards and
batteries

37.
Bionics
 Nature is an unparalleled designer and innovator.
Industrial companies have begun exploring new bionic
avenues in search of innovative lightweight design
concepts, as well as functional, adaptive and resource
efficient materials.

38.
Adaptronics
 The adaptive structure technology is based on functional integration by
combining conventional structures with active material systems, which
extend classical load-bearing and form-defining structure performance by
including sensor and actuator functioning. In connection with suitable
adaptive controller systems, adaptive structure systems can adapt to
their respective operational environment optimally.
 The adaptive structure technology pursues two main goals:
 1. Adaptronic allows the continuous intervention in structural-
mechanical and structural-dynamic characteristics of the complete
system.
 2. The adaptive structure technology is aimed at the optimization of
the structural system by replacing structure components with adaptronic,
multi-functional (effective in the sensor-actor sense) components to save
mass and designed space.

39.
NOISE CANCELLATION

40.
Textile Solutions
 Industry has been quick to recognize the potential
benefits of textile solutions – i.e. flexibility, low
weight, air permeability, weather resistance and high
mechanical durability.
 Tick-repellent textiles, air conditioning for barns, and
embroidered electronics
 Textile 4.0 would be a process chain of independent
production. Information carrier can be textile material
container, bobbin, warp beam, and fabric. Radio
frequency identification technology (RFID) and sensors
are basic to collect and store information, such as
equipment operation status, and maintenance
information.
 The plant will self-configure and self-optimize quickly
and flexibly to meet custom manufacturing orders.

41.
Nanotechnology,
Virtual Reality.

42.
Micro-Nano Area
 Microstructures and sensor systems,
 Intelligent laser processing systems,
 High-precision 3D measuring techniques,
 Energy harvesting applications

43.
Intelligent manufacturing you
can touch
 Smart Factory: Integrated manufacturing leads to
customized products! In the future, everything will be
integrated – now it depends on the network!
 Enterprise Resource Planning
 Manufacturing Execution System, MES
 Industry 4.0 is revolutionizing manufacturing by
gradually moving from closed systems to partially-open
systems and then, ultimately, to completely open
systems.
 More than within the company, intelligence-based and
information-based operations also should include
suppliers and contractors qualified to participate in
supply chains

44.
DIGITAL TWIN –
TECHNOLOGY THAT IS CHANGING
INDUSTRY
 https://www.slideshare.net/jayeshcspai/di
gital-twins-technology-that-is-changing-
industry

45.
World of Work 4.0
 Opportunity or risk?
 47 percent of workers could lose their job as a
result of automation and digitisation during the
next 20 years.
 Many new jobs will result from digitisation.
 Lifelong learning will need to be more naturally and
more systematically rooted in our education system.
 Flexibility is the Slogan

46.
Supply 4.0: Faster. More
flexible. More innovative
 The key to optimizing operational processes in an Industrie 4.0
strategy is a fully digitalized supply chain that allows the entire
flow of goods and processes to be controlled online, making it
transparent to participants. The increase in transparency results in
a reduction of transport damages and an improvement in quality.
 Characteristic of this are automated transactions and embedded
intelligence, optimized and connected data flows, and strategies
based on real-time data and simulations.
 Four key technologies:
 Supply chain visibility platforms/solutions,
 Big Data/analytics,
 Cloud computing,
 and Simulation tools.

47.
PLM
 In the discrete manufacturing industry it means Product Lifecycle
Management, whereas in the process industry it means Plant Lifecycle
Management.
 The backbone of this is digitalization : a central source for all data
regarding a product, from the initial idea and production to sales and
marketing.
 Action areas: PLM
 01: Digital models
 02: Smart products
 03: Smart factories
 04: Smart service

48.
MadeinChina_2025
https://www.slideshare.net/jayeshcs
pai/china-2025