Industry 4.0 is the integration of digital technologies into manufacturing and industrial processes. It's also known as the fourth industrial revolution. Industrial IoT networks, AI, Big Data, Robotics, Automation, Cyber-physical systems, Cloud computing, Cognitive computing, Smart manufacturing, Machine learning are the basics in adopting industry 4.0,

Industry 4.0 is revolutionizing how companies manufacture, improve, and distribute their products. It's creating a more connected ecosystem for companies that focus on manufacturing and supply chain management. For example, a connected supply chain can adjust to new information, like weather delays, and modify manufacturing priorities.



The name Industry 4.0 comes from Germany's Industry 4.0, a government initiative to promote connected manufacturing. The term Industry 4.0 was publicly introduced in 2011 at the Hannover Fair. The brief history of Industry 4.0 i.e. from steam to sensor: historical context for Industry 4.0



First industrial revolution



Starting in the late 18th century in Britain, the first industrial revolution helped enable mass production by using water and steam power instead of purely human and animal power. Finished goods were built with machines rather than painstakingly produced by hand.



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Second industrial revolution



A century later, the second industrial revolution introduced assembly lines and the use of oil, gas and electric power. These new power sources, along with more advanced communications via telephone and telegraph, brought mass production and some degree of automation to manufacturing processes.



Third Industrial Revolution



The third industrial revolution, which began in the middle of the 20th century, added computers, advanced telecommunications and data analysis to manufacturing processes. The digitization of factories began by embedding programmable logic controllers (PLCs) into machinery to help automate some processes and collect and share data.



Fourth Industrial Revolution

We are now in the fourth industrial revolution, also referred to as Industry 4.0. Characterized by increasing automation and the employment of smart machines and smart factories, informed data helps to produce goods more efficiently and productively across the value chain. Flexibility is improved so that manufacturers can better meet customer demands using mass customization — ultimately seeking to achieve efficiency with, in many cases, a lot size of one. By collecting more data from the factory floor and combining that with other enterprise operational data, a smart factory can achieve information transparency and better decisions.

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What technologies are driving Industry 4.0?

Internet of Things (IoT)

The Internet of Things (IoT) is a key component of smart factories. Machines on the factory floor are equipped with sensors that feature an IP address that allows the machines to connect with other web- enabled devices. This mechanization and connectivity make it possible for large amounts of valuable data to be collected, analyzed and exchanged. Government of India has taken initiatives in this direction and

13 digit numbering scheme has already been issued to various TSPs (Telecom Service provider) for M2M communication.


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Cloud Computing

Cloud computing is a cornerstone of any Industry 4.0 strategy. Full realization of smart manufacturing demands connectivity and integration of engineering, supply chain, production, sales and distribution, and service. Cloud helps make that possible. In addition, the typically large amount of data being stored and analyzed can be processed more efficiently and cost-effectively with cloud. Cloud computing can also reduce startup costs for small- and medium-sized manufacturers who can right-size their needs and scale as their business grows. As business scenarios evolve, the need to use superior computing capabilities to perform complex operations becomes commonplace. Reliance JIO is provding the cloud computing services in India.

JioCloud Compute powered by Microsoft Azure is a simple, scalable, secure and cost- effective solution that enables access to Virtual Machines, App Services and other virtualizations to build and deploy applications. This is on-demand, as per business requirements along with pay-as-you-go pricing for cost savings. With reduced price, maintenance, and various storage options available, you can transform and boost your business by focusing on core competencies. Cloud Compute is the future and Jio brings the best-in-class services to leverage Cloud advantage and develop your business. Jio Data Centers located in India assure secure access, savings, and support for all your compute needs.

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AI and Machine Learning

AI and machine learning allow manufacturing companies to take full advantage of the volume of information generated not just on the factory floor, but across their business units, and even from partners and third-party sources. AI and machine learning can create insights providing visibility, predictability and automation of operations and business processes. For instance: Industrial machines are prone to breaking down during the production process. Using data collected from these assets can help businesses perform predictive maintenance based on machine learning algorithms, resulting in more uptime and higher efficiency. In this regard GoI has framed the company named AI4ICPCS under section

8 and under mentorship of IIT Khadkapur.



The nodal ministry is DST. IIT Kharagpur AI4ICPS I Hub Foundation (AI4ICPS) is the Technology Innovation Hub (TIH) on Artificial Intelligence (AI) and Machine Learning (ML) for Interdisciplinary Cyber-Physical Systems (ICPS), established by the Indian Institute of Technology Kharagpur under the aegis of the National Mission on Interdisciplinary Cyber-Physical Systems (NM-ICPS) of the Department of Science and Technology (DST), Government of India. AI4ICPS focuses on technology innovation in AI and ML for intervention to ICPS across industry sectors in healthcare, precision agriculture and nutritional security, manufacturing, energy, transportation, environment and pollution, communication technology, education, judiciary, and legal.



We are aligned with the national network of all the Technology Innovation Hubs to research and develop new knowledge, technology solutions, technology transfer and skilled human resources and build a salubrious ecosystem for entrepreneurship to enable the nation to become a global industrial power center of ICPS. t is established with the objective of translating academic research resulting in pre-/prototypes at Technology Readiness Level (TRL) 3 to 7 ready scalable products and processes for the Industry. This is enabled through the Industry - TIH - Academia co-working Product Engineering Group (PEG). We address technology innovation challenges primarily in the areas of AI and ML to meet the requirements of current-age and future-ready ICPS for India and the world.



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Edge Computing



The demands of real-time production operations mean that some data analysis must be done at the “edge”—that is, where the data is created. This minimizes latency time from when data is produced to when a response is required. For instance, the detection of a safety or quality issue may require near- real-time action with the equipment. The time needed to send data to the enterprise cloud and then back to the factory floor may be too lengthy and depends on the reliability of the network. Using edge computing also means that data stays near its source, reducing security risks.



Cyber Security



Manufacturing companies have not always considered the importance of cybersecurity or cyber-physical systems. However, the same connectivity of operational equipment in the factory or field (OT) that enables more efficient manufacturing processes also exposes new entry paths for malicious attacks and malware. When undergoing a digital transformation to Industry 4.0, it is essential to consider a cyber-security approach that encompasses IT and OT equipment.

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Digital Twin



The digital transformation offered by Industry 4.0 has allowed manufacturers to create digital twins that are virtual replicas of processes, production lines, factories and supply chains. A digital twin is created by pulling data from IoT sensors, devices, PLCs and other objects connected to the internet. Manufacturers can use digital twins to help increase productivity, improve workflows and design new products. By simulating a production process, for example, manufacturers can test changes to the process to find ways to minimize downtime or improve capacity. Let us discuss Industry 4.0 in Manufacturing Sector.





Manufacturing 4.0 is about unlocking the value of the Fourth Industrial Revolution, or Industry 4.0, which can help an organization thrive — even amid disruption. With the infusion of digital technologies in facilities and operations, manufacturers are redefining possibilities for resource and production process efficiency, asset utilization, labor productivity, quality enhancement, time to market reduction, and service value-add.

“Smart manufacturing,” which is driven by the analysis of data generated by advanced sensors, software, and robotics, can lead to improved decision making. Heightened visibility and insights are generated from the combination of production data and operational data within an organization and across ecosystem partners. In addition, the potential value of data sharing in manufacturing process optimization has been estimated at over $ 10 0 billion.



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Data rich, information poor

As part of Industry 4.0, cyber-physical models and digital integration of new technologies across the value chain help increase efficiency and provide mass customization capability. The convergence of information technology (IT) and operational technology (OT) systems creates interconnectivity between autonomous manufacturing equipment and broader computer systems.

However, the recent survey done by IBM of 2,360 manufacturing industry executives in 32 countries revealed that manufacturers are not tapping the full power of big data, and many face significant technology barriers. Despite the revolutionary potential of data insights in manufacturing, most organizations are not using data from equipment, processes, and systems in any meaningful way to draw insights for continuous process improvement.

For example, predictive maintenance involves the continuous collection and analysis of sensor data to identify faults prior to failures and prompt interventions only when needed. But only a quarter of organizations are optimizing asset or equipment maintenance schedules based on analysis of failure modes and balancing reliability and cost.

Fewer than 1 in 5 have real-time access to important manufacturing data across the enterprise, which could include useful unstructured data from spreadsheets, industrial social media, email, text files, video, or CAD.

Driving business value through Industry 4.0

Executives identify a combination of technologies that are important to advancing their manufacturing objectives. More than three quarters cite AI, which is not surprising given AI-generated insights help improve visibility and predictability of manufacturing operations. Security technologies, cited by 70%, are necessities with the continued risk of cybersecurity attacks in IT and OT environments.

Cited by almost 68%, cloud computing provides connectivity and can run applications and store data. And the Internet of Things (IoT), cited by 67%, connects sensors and devices to networks to take advantage of large amounts of real-time data. For example, if an assembly line is experiencing a disruption, products can be rerouted or delayed to help reduce wasted time and cost.

The combination of edge- and cloud-computing infrastructure provides localized optimization and connected assets for smart manufacturing. However, only 84% of respondents are in the earlier stages of edge computing maturity, with nearly half at the pilot stage and the rest having advanced to implementation in some production lines.



Executives rank the most important technologies driving success in manufacturing.

Not surprisingly, manufacturing respondents tell us their top objectives are increasing production yield, improving product quality, addressing sustainability, and reducing machine downtime. Yet, there is a gap between ambition and performance: Despite these objectives, only 36% of respondents are maintaining desired throughput and yield to a significant or very great extent.

However, our research revealed a group of organizations that are ahead of their peers in terms of digital transformation. Having instilled a data-driven culture for their organizations, these Data Transformers offer a model for other organizations to follow.

The Manufacturing 4.0 advantage

In addition to surpassing their peers in digital maturity, Digital Transformers also stand out due to superior business and operational performance. 71% say they outperformed their competitors in revenue growth over the last 3 years. Data Transformers also exhibit both decision-making and mass customization success.

Dependent on a transparent, efficient supply chain, Data Transformers have implemented AI to a greater degree than their peers for procurement and logistics. 50% have fully implemented or implemented at scale raw material/component/subassembly procurement, and 41% have done so for logistics.

By leveraging technologies to align business objectives with improved outcomes, these data mature organizations are distinguishing themselves through their insights, cyber resilience, enterprise architecture, manufacturing excellence, workforce capabilities, and digital integration.

Overall, Data Transformers stand out in 6 key areas:

— Tap the potential of data.

— Achieve cyber resilience.

— Create an enterprise architecture connecting the plant floor to business systems.

— Increase manufacturing excellence with technology.

— Embrace the manufacturing worker of the future.

— Integrate digital with manufacturing operations and management.

Cost-effective digital manufacturing solutions are needed to keep factories and supply chains running smoothly while producing high-quality products.

Download the report to discover how industry leaders are leveraging Manufacturing 4.0 for greater customer value and ongoing operational improvements that help drive productivity and profitability.

Conclusion

The benefits of adopting Industry 4.0 norms in manufacturing sector have changed the scenario. The major benefits are as mentioned below:

Improved Productivity and Less Machine Downtime

In simple terms, Industry 4.0 technologies enable you to do more with less. In other words, efficiently. Your production lines will also experience less downtime because of deeper levels of integration, enhanced machine monitoring, and automated/semi-automated decision-making. OEE (Overall

Equipment Effectiveness) will improve, too, as your facility moves closer to becoming an Industry 4.0

Smart Factory.

Improved Efficiency

Multiple areas of your production line will become more efficient as a result of Industry 4.0-related technologies. Some of these efficiencies are mentioned above – less machine downtime as well as the ability to make more products and make them faster.

Other examples of improved efficiency include faster batch changeovers, automatic track and trace processes, and automated reporting. NPIs (New Product Introductions) also become more efficient as does business decision-making.

Optimized Supply Chain Management and Security

With Industry 4.0 technologies, processes, and systems, you will have better visibility across your entire supply chain. Your supply chain will also become better connected, enabling real-time monitoring with enhanced communication and collaboration. This can, for example, make it possible to identify bottlenecks and other supply chain problems before they have an impact on production line output. Having this advanced knowledge means you can take mitigation steps. Your supply chain will also become more resilient and agile, improving your ability to respond to changing market conditions and customer demands. Optimized Product, Production Line, and Factory Lifecycles with Digital Twins Digital twin technologies capture data in the physical world to create a digital replica that updates in real time. That replica could be a twin of a product, a production line in your facility, or your entire factory. Having this digital twin allows you to optimize performance and efficiency and test different scenarios without impacting real-world output. You will also be able to identify areas of innovation and improvement.

Empowered People

With Industry 4.0 technologies, your people will have access to better data to give them enhanced oversight as well as the decisions. Furthermore, you can eliminate the need for your people to work on repetitive tasks. With automation technologies and advanced workflows taking on repetitive tasks, your team can concentrate their efforts on value-adding tasks.

Increased Knowledge Sharing and Collaborative Working

Traditional manufacturing plants operate in silos. Individual facilities are silos as are individual machines within a facility. This results in minimal collaboration or knowledge sharing.

Industry 4.0 technologies allow your production lines, business processes, and departments to communicate regardless of location, time zone, platform, or any other factor. This enables, for example, knowledge learned by a sensor on a machine in one plant to be disseminated throughout your organization.

Best of all, it is possible to do this automatically, i.e., machine-to-machine and system-to-system, without any human intervention. In other words, data from one sensor can instantly make an improvement across multiple production lines located anywhere in the world.

Flexibility and Agility

The benefits of Industry 4.0 also include enhanced flexibility and agility. For example, it is easier to scale production up or down in a Smart Factory. It is also easier to introduce new products to the production line as well as creating opportunities for one-off manufacturing runs, high-mix manufacturing, and more.

Makes Compliance Easier

Complying with regulations doesn’t have to be a manual process in industries like pharmaceutical and medical device manufacturing. Instead, Industry 4.0 technologies make it possible to automate compliance, including track and trace, quality inspections, serialization, data logging, and more. Improved Product Quality

Industry 4.0 solutions can move quality functions from inspection rooms to the production line. This can mean real-time, in-line inspection with increased automation. The result is an inspection process that evolves from a go/no-go approach to one that is continuously measuring and analyzing to improve processes and identify quality issues so they can be corrected before they get to a failure stage.

An increase in automation will also reduce human error in the quality function and automate the collection, transmission, and storage of data.

Better Customer Experience

Industry 4.0 also presents opportunities to improve the service you offer to customers and enhance the customer experience. For example, with automated track and trace capabilities, you can quickly resolve problems. In addition, you will have fewer issues with product availability, product quality will improve, and you can offer customers more choice (see the point about increased profitability below).



Summary:
The benefits of Industry 4.0 span manufacturing, business operations, compliance, quality, and the customer experience. As a result, the technologies and solutions that come under the Industry 4.0 umbrella are transforming manufacturing industries across the world.

While industries in the life sciences sector are generally behind other industries in terms of Industry 4.0 evolution, there are significant gains that can be achieved through careful planning.

Additionally, regulators are adapting to the realities of digital transformation and Industry 4.0, enhancing the potential even further. Other drivers are also accelerating the push towards Industry 4.0 solutions, including challenges in recruitment and the need to increase resiliency. With the benefits outlined above, it is also possible to get a healthy return on investment.

Staying competitive in a digitally transformed world is about continuous improvement with an Industry 4.0 focus.