2. Commitment to vision of Smart
Factory
Industry 4.0 environment are for the strong customization of products under the conditions of mass
production. The automation technology is improved by the introduction of methods of self-optimization,
self-configuration, Self-diagnosis, cognition and intelligent support of workers in their increasingly
complex work
3. Technologies and concepts for Value
Chain Organization
Solutions that include:
Embedded system – Links the Physical elements to computational elements
Internet of Things
Internet of Services
4. Design Principles of Industry 4.0
Interoperability - The ability of cyber-physical systems, humans and Smart
Factories to connect and communicate with each other via the Internet of
Things and the Internet of Services
Virtualization - A virtual copy of the Smart Factory which is created by linking
sensor data with virtual plant models and simulation models
Decentralization - The ability of cyber-physical systems within Smart
Factories to make decisions on their own
Real-Time Capability - The capability to collect and analyze data and provide
the derived insights immediately
Service Orientation - offering of services via the Internet of Services
Modularity - flexible adaptation of Smart Factories to changing requirements
by replacing or expanding individual modules
5. Impact areas of Industry 4.0
Machine safety
Industry value chain
Workers
Socio-economic
Industry Demonstration
6. Key Problem Areas in Manufacturing
Quality, Regulation, Compliance
Consistent quality
Cost Control
Reduce rejection ration, scrap and utility management,
Vendor management, quality raw material at lowest price
Safety
Automated safety and protection devices, uninterrupted safe operations
Innovation
Integrated SCM, Process improvement, Process analytics and efficiency
Growth
Expansions,
Automation and speed improvement and increase productivity
Asset Management
Sustainability
Predictable operations, maintainability and Productivity
7. Transformation Strategies
Digital enterprise software suite
Develop scalable IT systems
Manage end-to-end processes
Increase Social Interactions
360 degree information availability
Eliminate Hierarchies
8. Elements of growth for Industry 4.0
Devices – smart sensors, controls, software applications, obtain and share real
time data, enable autonomous actions
People – connectivity across business functions, geographies and real time.
Provide intelligent design, operations and maintenance as well as high
quality of service and safety
Processes - information sharing on global manufacturing value chain from
supplier to customer – flexible and adaptable supply chain
Connectivity -
9. Realizing the vision of Industry 4.0
Industry
4.0
Processes
CollaborationTechnology
10. Industry 4.0 - components
Technology
Internet of Things
Cloud Platforms
Big Data
Wireless
Intelligence
Collaboration
Integrated Industries
IP Centralization
Social Innovation
Processes
• Internet of
Services
• Lifecycle
assessments
• Sustainable
Manufacturing
11. Industrial IT and Manufacturing
applications
Integrated enterprise ecosystem
ERP
PLM
MES – Production planning, scheduling,
tracking, traceability
Manufacturing Enterprise
Ethernet devices
VR predictive maintenance
Asset Management Apps
3D operator training Assistance
Industrial Internet
SCADA, HMI
Cloud IT infrastructure
Wireless Communucations
Mobile maintenance
Social Media Apps
Data Processing and Analytics
Commercial IT
Remote Home control apps
Cyber security apps
Warranty Management
12. Big Data Analytics
Techniques
Data Acquisition
Management Decision
Simulation
Contextualization
Action based Intelligence
Results
Maximizing asset utilization
Reducing energy consumption
Optimizing Production
13. Protocols used
Connectivity
RS232
Modbus
Wireless
USB
NFC
QR Code
Link Protocol Layer
ZigBee
BLE
Bluetooth
Wifi
Ethernet
GSM
RFID
Transport
IPv4
IPv6
Session Communication
HTTP
FTP
Telnet
SSH
AMQP
XMPP
14. Example - Manufacturing plant
•Pay per use model•Machine
optimization
•Energy optimization
•Resource
optimization
•Asset Analytics
•Energy Analytics
•Process Data
Analytics
•Industrial Cloud
platform
•Ecosystem for
Partners
•Modularization
Plant Data
Asset
Optimization
Cloud
infrastructure
Process
Optimization
15. Conclusion
A systematic transformation across existing structures, systems, processes and
strategies is required to reap benefits from Smart Manufacturing Initiative
Existing systems need to be evolved keeping the result oriented ness and
within the priorities of organization’s profitability and efficiency
improvements.
Rest assured that initiative will lead to New business models, more value and
experience to customers and profitability.