The 'Hyperconnected' world of Industry 4.0 (I4.0) - And Why it will Challenge us to the very Core

The term 'Industry 4.0' (I4.0) refers to the Fourth Industrial Revolution. I4.0 was first publicly introduced in 2011 as “Industrie 4.0” by a multi-disciplinary group of representatives under an initiative to enhance the German competitiveness in the Manufacturing Industry.

It took about 7-8 years for much of the developed economies and industrialised nations to seriously pick-up the buzz around I4.0. A closer study of its key tenets would reveal that it is, in its very essence, a Digital Transformation, about to drive an Exponential Growth through Accelerated Technology Transformation.

Key Tenets of I4.0

Being essentially a Digital-Led Transformation, the ‘Hyper-Connectivity’ forms the very Core of I4.0 and a ‘Cyber-Physical Production System (CPPS)' it’s very heartbeat. Together they create a formidable Enabler for the Exponential & Accelerated Growth.

CPPS can be explained as a web of Inter-Connected and Integrated Machines, connected with Material Replenishment systems, Orders/ Demand & Forecast Trends, Product Design (through to its entire life cycle with a market feedback loop), Autonomous Production plan generator across all its product portfolios, Predictive Maintenance alerts (as against a high-cost Preventive maintenance), Network of Multi-mode/Multi-channel Transportation and Autonomous Optimization of Distribution plan to Maximize Customer Reach & Fulfilment – and all of these at Real-Time, high in Flexibility while yet offering a Customized / Individualized Tailor-made solutions/products to the Customer of the future, at the Same Cost as that of a mass-produced product of today.

So in effect, the CPPS brings the Real & the Virtual World together to enable the machines to act Intelligently, Autonomously and to collect live data, analyze them and make Smart Decisions On-the-Go. Machines talking to Machines within its holistic eco-system thru IOT or IIOT (Industrial Internet of Things), with People in the extended Network thru IOP (Internet of People), Big Data and its intelligent analysis form the very basis of the functioning of the CPPS, exploiting the power of AI / ML and AI enabled Deep Learning to its ultimate limits.

Manufacturing 4.0 – Machine Talking to Machine with People in the Loop

A closer look at Tomorrow's Manufacturing (Mfg 4.0) would reveal at its core a 'Smart Factory' with Intelligent, extensively Networked and Connected Robots with advanced Robotics (Sensors), highly Autonomous, Cognitive and capable of Digital Supervision - i.e essentially Putting Human Intelligence, Skills and Expectations into the Machine. The huge upside of the CPPS would be Machines learning from all other Connected Machines in the network through its past performance (in Digitized form), constantly Self-Improving through in-built AI/ML & Deep Learning.

Logistics 4.0: 24x7 Connected Network feeding information to Machines in Factory:

Millions of Moving Trucks/Trailers carrying parts/ components/ raw material & finished products can be accessed on a Global Common Network/ Grid connected to each Truck’s Onboard Cloud-Connected computer, allowing Value-add even while on the move by continuously suggesting AI-enabled Alternate Routes/ Destinations or latest critical supply chain updates/informations or an imminent change in business dynamics or Acts of God etc, thereby Maximizing the value proposition of the goods-in-Transit, converting the In-Transit Inventory from being a mere Overheads/Costs to an Asset available as immediate Value to customers, creating the Global In-Transit Trucks/Inventory pool into a huge potential ‘Warehouse/Assets on Wheels' to be Monetized on-the-go.

Organization 4.0 / Leadership 4.0

Even though I4.0 is essentially an industrial 'Revolution', but it has to necessarily undergo a gradual and holistic Evolutionary Journey, the change being just too big & transformative..! The future of Manufacturing 4.0 would demand an overhauling of Organizational Culture & Behavior, Business Model and work practices, breaking Functional silos and Structures and creating an all new 'Learning Organization', wherein Human and Machines give space and adapt to each other to Co-work, Collaborate and Co-create. In doing so, it is the Human Centricity, Human Ingenuity and Human Intuitiveness that would need utmost care, consideration and management.

But change is always met with Resistance, let alone a Revolutionary one…'Status-quo' is just so sweet and easy, isn't it.!! Precisely why I4.0 would demand the utmost Drive, Focused Attention, Strongest Resolve & a Firm Intent from the organizational Leadership.

Finally, Industry 4.0 is about touching THAT which is hitherto Un-touched, Un-manifested and Un-realised, but as J Krishnamurti (1895-1986) aptly puts it “ One is never  afraid  of the Un-known; one is afraid of the Known coming to an End ”

Are we ready to Let-go, Un-learn, Re-learn, Embrace and finally Transform..?

Amlan Bose ; 14th Sep’20 ; Chennai, India