Industry 4.0 Initative

1. Smart Manufacturing –
Industrial Automation
Solutions
Industry 4.0 initiative
By Unmesh Ballal

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.