Revolution in the Industries with “Industry 4.0”
Industry 4.0 is revolutionizing how companies manufacture, improve and sell their products. Manufacturers are adapting to newer technologies, including the Internet of Things (IoT), cloud computing and analytics, and AI and machine learning, into their manufacturing facilities and daily operations.
Industry 4.0 emerged in 2011 from the German government's high-tech strategy project promoting the computerization of production. In fact, the term "Industry 4.0" was publicly introduced that year at the Hanover Fair.
Today everyone is associated with the fourth industrial revolution known as Industry 4.0 - the alliance between physical assets and advanced digital technologies - such as the Internet of Things (IoT), artificial intelligence (AI), robots, drones, autonomous vehicles, and 3D printing and computing. cloud and others connected, able to communicate, analyze, and act. Enterprises adopting Industry 4.0 are more agile, responsive, intelligent, and therefore better equipped for data-driven solutions.
According to a comprehensive research report by Market Research Future (MRFR), “Market Industry 4.0” information by technology, end-user, application and region – estimates that the market size will reach $280 billion by 2030 and grow at a CAGR of 21% growth by 2030. Higher quality, more advanced products and processes that deliver higher margins lead to more rapid and sustainable innovation. Industry 4.0 is revolutionizing many aspects of manufacturing operations, including real-time production monitoring, improving metric accuracy and manufacturing efficiency.
Current smart factories are equipped with advanced sensors, embedded software and robotics that collect and analyze data and enable better decision-making. Greater value is created when data from manufacturing operations is combined with operational data from ERP, supply chain, customer service, and other enterprise systems to create a new level of visibility and insight from previously hidden information.
This digital technology results in increased automation, predictive maintenance, self-optimized process improvements, and most importantly, new levels of efficiency and customer responsiveness that were previously impossible.
The development of smart factories offers the manufacturing industry a tremendous opportunity to enter the fourth industrial revolution. Analysis of the vast amounts of data collected by sensors in factories provides real-time insight into production assets and can provide tools for performing predictive maintenance to minimize equipment downtime.
The use of high-tech IoT devices in smart factories results in higher productivity and better quality. Replacing the manual inspection business model with AI-based visual insights reduces production errors and saves money and time. With minimal investment, quality control personnel can set up cloud-connected smartphones to monitor manufacturing processes from virtually anywhere. By implementing machine learning algorithms, manufacturers can find faults immediately rather than later when repairs are more expensive.
Industry 4.0 concepts and technologies can be applied to all types of industrial companies, including discrete and process manufacturing and segments of the oil and gas, mining, and other industries.
Fourth industrial revolution
We are now in the fourth industrial revolution, also known as Industry 4.0. Characterized by increased automation and the use of smart machines and smart factories, informed data helps produce goods more efficiently and productively across the value chain. Increased flexibility, enabling manufacturers to meet customer requirements through mass customization better. By collecting more data from the factory floor and combining it with other companies' operational data, intelligent factories can achieve information transparency and better decisions.
Benefits of Industry 4.0?
Increased efficiency in production
With increased automation and the ability to continuously improve, smart factories can increase their efficiency to previously thought impossible levels. Each resource is automatically optimized for minimal loss.
More innovation potential
Industry 4.0 is all about innovation. With data collected from connected devices like the Internet of Things, the design team knows what works and what doesn't. This data will drive their innovation for new and better products and systems.
Quick response to customer requirements
Customer needs are changing faster than many industries can keep up. They want new designs, new technologies, and new features every few months. Industry 4.0 is designed for flexibility so you can react to market dynamics faster than the competition.
Reduced costs and higher profit margins
You achieve lower overall operating costs through better resource utilization, less waste, fewer quality issues and less downtime. Despite the large initial investment, you have a much higher profit margin to achieve a return on investment within a few years.
Quality Assurance
Industry 4.0 gives you the opportunity for impeccable product quality. You can also ensure factory perfection by tracking products during shipping. By eliminating that elusive 1% of defective products, you too can keep costs to a minimum.
Fluid collaboration
All devices, systems and people are connected via cyber-physical networks to form the Internet of Things. This will include not only internal departments, but also supply lines, marketing teams, and even higher levels of management. This connectivity will enable knowledge sharing for optimization and innovation improvement. Regardless of location or platform, you can communicate and collaborate without human intervention.
Technology pushes Industry 4.0 forward
Internet of Things (IoT)
The Internet of Things (IoT) is a key component of smart factories. Factory machines are equipped with sensors with IP addresses that allow machines to connect to other internet-enabled devices. These mechanisms and connectivity make it possible to collect, analyze and share large amounts of valuable data.?
Cloud Computing
Cloud computing is the cornerstone of any Industry 4.0 strategy. Full implementation of intelligent manufacturing requires connectivity and integration of engineering, supply chain, manufacturing, sales, and service. Cloud helps make it happen. In addition, the large amounts of normally stored and analyzed data can be handled more efficiently and cost-effectively with the cloud. Cloud computing can also lower startup costs for small and medium-sized manufacturers who can scale their needs and scale appropriately as their business grows.
AI and machine learning
AI and machine learning allow manufacturing companies to take full advantage of the amount of information generated not only in factories but also across their lines of business and even from partners and third-party sources. AI and machine learning can create insights that provide visibility, predictability, and automation of business operations and processes. For example, industrial machines tend to break down during the manufacturing process. Using the data collected from these assets can help companies perform predictive maintenance based on machine learning algorithms, resulting in more uptime and greater efficiency.
Solar-blind Photodetectors
Solar-blind photodetectors are insensitive to infrared, visible, and near UV light but sensitive to ultraviolet light with wavelengths below about 300 nm. Note that the solar radiation on Earth also extends to the ultraviolet to some extent; Outside the atmosphere, there is a much higher proportion of UV. Solar-blind detectors can, therefore, still show some response when exposed to sunlight in space.
?Solar cameras can be used to monitor power lines where electrical discharges can be easily detected by their UV radiation. An example of a military application is the detection of high-temperature flares from rocket motors observed under intense sunlight.
Cyber Protection
Manufacturing companies do not always consider the importance of cybersecurity or cyber-physical systems. However, the same connectivity of control equipment in the factory or in the field (OT) that enables more efficient manufacturing processes also opens new avenues for malicious attacks and malware. In the digital transformation to Industry 4.0, it is crucial to consider a cybersecurity approach that includes IT and OT tools.
Digital Twins
The digital transformation that Industry 4.0 offers have enabled manufacturers to create digital twins that are virtual replicas of processes, production lines, factories, and supply chains. Digital twins are created by downloading data from IoT sensors, devices, PLCs, and other objects connected to the internet. Manufacturers can use digital twins to increase productivity, improve work processes, and design new products. For example, manufacturers can test process changes by simulating a manufacturing process to find ways to minimize downtime or increase capacity.
Related Solutions?
Consulting Services in Operations: Count on Tahion.pro's specialists to help you model and execute your vision for IoT-enabled connected operations, enabling you to achieve new levels of agility and flexibility.
?Advanced Inspection Solutions: Tahion.pro has partnered with OFIL Systems , catering to clients with various inspection solutions like:
?Apart from the listed areas, OFIL Systems also caters to industries related to Transportation, Electric Vehicles, Aerial scanning, Fire & Safety etc.?The company aims to enable autonomous decision-making processes, real-time monitoring of assets and processes, and real-time connected networks to create value through early stakeholder engagement and vertical and horizontal integration.
Dashboard for Analysis: At Tahion.pro , we have catered to various manufacturing clients where we have collated data and developed dashboards by which they can conduct/ take possible decisions for the betterment of the company.?
New products and services are being developed based on merging AI and IoT technologies. Other technologies like blockchain and edge computing are also becoming more common and their incorporation with IoT offers new applications as well. Soon, this technology will explode with new benefits that will facilitate the creation of a connected, intelligent and intelligent world. For more such information, kindly connect with us at [email protected] where we can discuss your pain and assist you in building the right solutions for you.