Technology is having an undeniably transformative impact across all aspects of society. People spend increasing amounts of time using digital devices for work and pleasure. In the context of manufacturing, this change is referred to as The Industry 4.0, or the 4th Industrial Revolution. This involves the automation of tasks that used to be carried out manually. But which types of technologies are being adopted? What benefits are manufacturers seeing? And how is the human workforce being affected? We’ll focus on such key questions here.
The Core of Industry 4.0
The roots of Industry 4.0 can be traced back to 1961, with the introduction of a robotic arm at the New Jersey factory of General Motors. The Unimate was able to perform a wide range of tasks as skillfully as human workers, but without getting tired. Such benefits have increasingly been realised through the integration of cyber-physical systems, the Internet of Things (IoT) and advanced technologies into manufacturing and beyond.
Industry 4.0 differs from earlier industrial revolutions, most obviously in the increased adoption of such advanced technologies. Where the focus was previously on manual skills, there’s now an emphasis on the integration of connected systems, with previously unseen levels of automation and control. These technologies allow for real-time data collection and analysis, with transformative effects on production line speed and predictive maintenance. The pace of technological advancement and adoption is also much greater than in previous revolutions.
Industry 4.0 Technologies
IoT and the IIoT (Industrial Internet of Things) are two of the key technologies defining Industry 4.0. This can be seen with the connection of interrelated devices to the internet for the transfer and sharing of data. As an example, machine data may be transferred to an app for the monitoring of performance and maintenance requirements. This depends on the connection of sensing devices, which collect and send accurate data to the cloud. Actuators can also be set up to trigger actions, optimising production with minimal need for human input.
These technologies are also having revolutionary impacts:
Artificial intelligence (AI)
This refers to the integration of digital systems able to perform tasks that have traditionally been carried out by people. With increasingly advanced analytical, problem-solving, and decision-making capabilities, such technologies are making a significant difference in the manufacturing space. AI is enhancing production line efficiency and quality, making for the reduction of costs and delivery of products that better meet customer expectations. AI systems also free human workers from boring and repetitive tasks.
Machine learning and predictive analytics
Directly linked with AI, machine learning (ML) is as it sounds - the process of machine learning from the collection of data. As the volume of data builds, the machines can make more accurate and dependable predictions. Machine learning also allows for the improved identification of anomalies, such as products that have slight, yet significant, defects. The capacity for production line predictions also means that adjustments can be made for the reduced risk of any costly downtime.
Big data and cloud computing
Big data refers to the massive amounts of digital information, specific to manufacturing in this case. The storage, processing, and analysis of such data is becoming more of a challenge given the increased integration of digital systems in industry 4.0. However, the cloud has great capacity for the collection of data in various formats. Minimising the demand on internal systems, cloud computing enables real-time access to manufacturing data for improved decisions, operations, and customer experiences.
Robotics and automation
As mentioned, the first factory robot was introduced more than 60 years ago. However, the pace of robot manufacturing and adoption has accelerated, with robots now able to perform highly intricate processes with precision. While the UK has lagged behind many other nations, there is a trend of increased investment in robotics over the coming years – with manufacturers realising such benefits as enhanced product quality, waste minimisation, and reduced costs and replace with – this will certainly allow UK firms to compete more effectively. The automation of tasks in the dull, dirty, and dangerous categories will also aid worker satisfaction.
Digital twins
Digital twins are visual representations of physical objects, systems, or processes from the real world. For instance, you might have a digital twin of a factory floor machine. The integration of sensors would allow for the collection and transfer of data specific to the behaviour and performance of the real-world machine. Tests could then be run in the digital environment to see the effects of changes and identify possible improvements. Going beyond the static snapshots taken in simulations, digital twins enable continuous updates based on real-time data.
The Role of IoT and IIoT in Industry 4.0
Of all the game-changing technologies, the IoT and IIoT are arguably having the greatest impact. As mentioned, the IoT enables real-time data exchange across connected systems for the optimisation of manufacturing processes. Combined with machine learning and AI, the IoT can be relied upon for the identification of key changes to increase productivity and quality.
The transformative effects of the IIoT have been realised across a range of industries. For instance, automotive companies such as Jaguar Land Rover have integrated the IIoT for production process monitoring, leading to increased safety and reduced downtime. Companies such as BMW and Siemens have also used the IIoT to create digital twins of their factories for the simulation and optimisation of production.
Overcoming Challenges and Preparing for the Future
Despite the recognised benefits, there are challenges to be overcome in the adoption of such transformative technologies. These technologies are becoming more affordable. However, there’s a lack of infrastructure and staff with knowledge of how to make full use of such advanced systems, but there are more machine system integrators that can help SMEs with any factory transformation. Support is also being provided by leading trade associations such as the PPMA, part of Automate UK.
While there’s great cause for excitement over the potential of Industry 4.0, companies are advised to take a gradual approach to technological adoption, start with some simple tasks. Besides spreading the expenditure, this will also allow staff to adjust and learn the optimum use of such advanced systems. Investments should also be made in the aim of overcoming specific challenges, such as limiting the need for maintenance and unplanned downtime. The adoption of an AI-driven and IoT-enabled infrastructure will be key.
These trends look set to shape the future of Industry 4.0:
- AI and ML playing vital roles in predictive maintenance, production optimisation, and decision-making
- Increasing adoption of autonomous AI-driven systems for tasks that used to be performed manually
- Greater reliance on digital twins for virtual testing and process optimisation
- More human-machine collaboration, leading to improvements of safety and productivity
- Continued use of the IIoT for real-time data exchange and improvement of operational efficiency.
The ongoing development and adoption of Industry 4.0 technologies will make for a smarter and more connected industrial future. Businesses must embrace such technologies for long-term competitiveness. As Deloitte’s Managing Director of Global Industries Gary Coleman has said, “with the swift pace of change and disruption to business and society, the time to join in is now.”