Industry 4.0 : Relevance to your industry

© Utthunga Technologies Pvt. Ltd. 2020
Industry 4.0 : Relevance to your industry
Presented by:
Utthunga IIoT Products Team
Utthunga for IIoT

Company Overview
500+
PROFESSIONALS
12
Germany
USA
Japan
HQ & Development Centre:
Bangalore India
SERVICES SOLUTIONS
Product FOCUS
Engineering IIoT, Cloud & Big
Data Analytics
Embedded
Software
& Hardware
Digital
Services
Solutions
Quality
Engineering
Application
Software
Engineering
Process
& Factory
Power &
Utilities
Data
Connectivity
& Integration
Solutions
Custom
Solutions

Industry Associations
 Part of various Special Interest Groups
(Technical Specifications, Architecture, Test
& Certification and Marketing)
 Involved in reference Application
Architecture, Design and Development
 Technology Outsourcing Partner
 PROFIBUS and PROFINET Competency
Center
 FDT Test & Certification Center
 Part of Global Expert/Certified Community
https://opcfoundation.org/about/opc-foundation/experts/
https://www.profibus.com/pi-organization/certified-people/

Building Blocks for Digital Transformation
INTEGRATION SOLUTIONS
INDUSTRIAL AUTOMATION
INDUSTRY SOLUTIONS
• Connectivity: Sensors, Edge devices
Gateways
• Integration Solutions - Protocol drivers,
OPC Classic & UA, Cloud, SCADA, ERP and
MES
• Field Instrumentation
• PLC/DCS/SCADA Automation systems
• Engineering software applications
• Operations management solutions
• Integration and simulation solutions
• Asset Insights
• Operation Efficiency & Analysis
• Energy Analysis & Optimization
• Predictive & Prescriptive Maintenance
• Remote Monitoring/Diagnostic

Speakers for today
About Speaker
Srivatsa is a seasoned enterprise architect, engineering lead
and entrepreneur with a total of 22 years of experience in
various start-ups and established corporates. His interest
areas are Industrial IoT, Digital Transformation, Artificial
Intelligence, ML/Algorithms, Cloud and Analytics.
His entrepreneurial, mentoring and innovation-seeking spirit
has helped in conceiving, designing and delivering several
products across varied domains like banking, aerospace, legal,
retail and telecom.
His rich expertise in software architecture, delivery, product
management, telecom network management, system
integration, OSS, cloud, mobility, managed services/XaaS,
analytics, AI and IIoT has helped him build strong teams to
develop products leveraging heterogeneous technologies
across domains.
Srivatsa Gorur

Speakers for today
About Speaker
Ravishankar Karanth
19+ Years of Sales & Marketing experience in Industrial Automation-
IIOT, OPC UA, Solution Software, Process and Factory Automation
Ravishankar had his previous assignments with Rockwell, Schneider,
Yokogawa serving Industrial Automation, Networking & MES
solutions market. He was engaged in different roles & responsibilities
of Sales & Proposal, Business Development & Project Management.
He worked across different industry segments including Pharma,
Manufacturing, Steel & Cement, Water and O&G and brings rich
domain expertise with him.

Quick Polls
Utthunga OPC Services

Industrial
Revolutions

Industry 1.0
Industry 1.0
The first industrial revolution happened in the late 1700s and
early 1800s. Optimized form of labor performed by people
through the use of water and steam-powered engines
Invention of Steam Engine was the main driver
Reduced raw materials, wastage, manpower, availability of
continuous machine power
Textile, Transportation, Foundry, Mining
Until the late 18th Century all creation of goods like Clothing, Armory, Buildings, Food, Crafts and so on were done
manually by hand and sometimes with the help of animals.
The first commercially successful steam engine, employing the piston-driven motion was designed and created
by Thomas Newcomen in 1712. James Watt designed a rotary motion steam engine that was safer and more
efficient, proving a key element in the Industry Revolution
Image Sources: britannica, oldbookillustrations

Industry 2.0 and 3.0
Industry 3.0
Starting in the 1970s, a third industrial
revolution slowly began to emerge, as
manufacturers began incorporating
more electronic Integrated Chips, and
eventually computer technology into
their factories
Advancement in Injection Moulding
machines, Plastics, Nuclear, Solar
Power, Software driven planning and
production, Robotic arms, PLC, Internet
Outsourcing, Supply chain
management, Automated Processes,
Better Standard of living, Industrial
Management
Industry 2.0
In the early part of the 20th century,
the introduction of electricity added
another source of power
Introduction of Assembly Lines,
Internal Combustion Engine
Mass production, New Industries,
Improved Sanitation, Water, Supply
and Living condition of workers,
creation of industrial townships
Automotive, Steel, Plastic, Railways,
Telegraph, Chemicals, Telephone
Image Sources: gettyimages, helistart, lego, wikipedia

Industry 4.0
Industry
4.0
Industry 4.0 has been defined
as a name for the current trend
of "Automation and Data
exchange in manufacturing
technologies, including Cyber-
physical systems, the Internet
of Things, Cloud Computing
and Cognitive Computing and
creating the smart factory”.
Decentralized intelligence
helps create intelligent object
networking and independent
process management, with the
interaction of the real and
virtual worlds representing a
new aspect of the
manufacturing and production
process.
The term Industry 4.0 was first
publicly introduced in 2011 as
“Industrie 4.0” under an initiative
to enhance the German
competitiveness in the
manufacturing industry. The
German federal government
adopted the idea in its High-Tech
Strategy for 2020.
The fourth industrial revolution
starts from 2011 onwards till
today. Interconnectivity through
the Internet of Things (IoT), access
to real-time data, and Security.
allows business owners to leverage
instant data to boost productivity,
improve processes, and drive
growth

Industry 4.0
Cyber-Physical Systems Internet Of Things
Cloud Computing Artificial Intelligence
• The cost of connectivity is dropping
dramatically, providing powerful potential
to connect people, assets, and information
across the Industrial enterprise
• Organizations can become more predictive,
drive powerful business outcomes by
bringing the value of data to
knowledge/wisdom to the minds of
Industry leaders.
• Production continuity, safety of both
physical and cyber-security are paramount,
sufficient vigilance is required to ensure
uptime and seamless operations without
overwhelming users or applications with
too much of data
• Taking advantage of Technology and being
competitive in the market

Building Blocks of Industry 4.0
Components
 Cyber Physical Systems
 Sensors
 Edge Gateways
 IT & OT Networks
 IOT Platforms
 Smart Factories, Smart plant
and Smart Applications
 Machine-to-Machine (M2M)
 Autonomous Robots
 Cyber Security
Cyber Physical Systems
Smart Sensor
Edge Gateways
IT & OT Networks
IOT Platforms Smart Factories,
Smart plant and
Smart Applications
Cyber Security

Building Blocks of Industry 4.0
Technologies
 Cloud computing
 Cognitive computing
 Artificial Intelligence
 Gigabit Ethernet , 4G/5G,
Bluetooth 5.0, WiFi
802.11ac
 Big Data & Analytics
 Internet of Services/
Blockchain
 Augmented Reality & Virtual
Reality
Cloud computing
Cognitive computing
Artificial Intelligence
Communication Infra
Big Data & Analytics
Internet of Services
/ Blockchain AR / VR

Changing views on Industry 4.0
• Building Resilience in Industrial operations is becoming a necessity
• Covid19 has exposed the vulnerabilities in supply chain networks
• Ongoing situation is expected to disrupt the industrial sectors in the coming years pushing
towards Industry 4.0 adoption
• Governments and Organizations worldwide are looking for alternative destinations in
Manufacturing. India is lagging in terms of spending on AI in manufacturing and other
sectors
• GOI push for “Atma Nirbhar Bharat” is expected to open up many opportunities in the
manufacturing sector in India.
• New use cases are expected to erupt due to increased health needs, social distancing,
remote work and operations etc.

Quick Poll

Industrie 4.0 Industry Relevance
(Use Cases)

Approaches for Smart Systems
Functional Integration Integrated Cyber Physical Systems
Embedded
System
Smart
Sensor
CPS Integrated
CPPS
IIoT Platform & Associated ApplicationsCommunicating Self Controlled Systems
Asset Health Monitoring
SMART LOGISTICS
Condition Monitoring
Remote Monitoring
Predictive Analytics & ML

Challenges faced by Industries for IIoT
Data Silos
Cost of Data
Integration
Data Security
Legacy Systems
No insights of
Logbook
Data Integrity
Issues
Challenges to Implementation
of IIoT

Use case 1 - Production Insights
Problem Definition:
No linkage of Production data with Energy/ Resources
consumed
Data integrity issues since readings and data points are
generally captured by Operator only.
No visibility into losses incurred to due to operational
problems(Tooling losses, setup losses etc.)
Applicable Industries:
Discrete manufacturing- Consumer goods, Auto
components etc.
Benefits:
• Achieve higher OEE by preventing unscheduled
downtime
• Digital Monitoring and tracking of OEE, helps to
reduce stops, slow cycles, rejection rate to achieve
TPM goals
• Track your SEC (Specific Energy consumption) and get
insights on reducing SEC

Use Case2 - Condition Based Management
Problem Definition:
Mechanical wear and tear, misalignment etc in rotating
equipment due to aging Lack of visibility into logbook
data for maintenance activities planning
Metals & Mining, Cement, Pharma, F&B, O&G, Power
Benefits:
• Holistic analytics module containing vibration FFTs
as well electrical signature.
• Visibility into maintenance log book online
• Reduction in Maintenance costs
• Achieve Higher OEE by preventing unscheduled
Down-time
• Track Asset’s remaining useful life(RUL) and achieve
better ROI
Vibration, electrical, temperature data monitoring of an asset &it’s Failure prediction
Temperature Sensor

Use Case3 - Energy Monitoring and Analytics
Problem Definition:
No visibility into Energy consumption across sections and
SEC(Specific Energy consumption)
No tracking of energy losses across the value chain
All kinds of Industries(Predominantly PAT Designated
Consumers- Steel, Cement, Power etc)
Benefits:
• Improvement in Energy efficiency
• Energy benchmarking Equipment-wise and Energy
Profiling
• Insights on Power Parameters like Power factor, Harmonics
and imbalances
• Get more insights on Equipment health and savings due to
low power quality parameters

Use Case4 - Asset Tracking
Problem Definition:
Inventory of spares, asset maintenance tracking,
keeping track of process parameters of an asset
Discrete Manufacturing Industries, EPC’s providing
O&M, Process Industries like Cement, Steel, Pharma
Benefits:
• Quickly and easily locate assets at any time at
though at real-time
• Improved efficiency and low cost
• Track and reduce asset loss and utilize assets more
efficiently
• Improve customer services through improved asset
tracking and management practices
• Assures accountability and accuracy with asset loss
and management
• Immediately know the exact location of the asset

Benefits of Industry 4.0
 Cost Optimization and Revenue maximization
 Better visibility across your Plant
 Reduces unscheduled downtime
 Improving working condition and sustainability
 Insights into operation enables informed decision making
 Higher business continuity through advance maintenance and monitoring
possibilities
 Technology adoption makes a company attractive to workforce as well as
provides competitive advantage
 Improved Customer experience
 Socio-economic factor

IIoT Webinar Series Calendar
17 July 2020 : Condition Monitoring using Vibration & Electrical signature in process Industry-
19 June 2020 : OEE & performance analytics in discrete Industry
5 June 2020 : IIOT Solutions for Pharma Manufacturing and Use cases
31 July 2020 : KPI Management
3 June 2020 : IIoT Relevance to your Industry

Utthunga Technologies Pvt. Ltd.
No. 8, 27th Cross, 2nd Stage,
Banashankari, Bangalore – 560 070
Phone: +91-80-68151900
Mail: contact@utthunga.com

Industry 4.0 : Relevance to your industry

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