Industry 4.0 is a term that has been growing in prominence for a number of years now and while some companies have embraced it, others are more wary of what it is and what can be gained from adopting it. Here we get under the skin of the digital technologies driving Industry 4.0 and highlight some of its benefits and use cases.
Now more than an overhyped buzzword, Industry 4.0. will and is transforming the way we produce products. Through the use of advanced technology this fourth industrial revolution is quite simply revolutionising traditional manufacturing and industrial practices.
Whereas the first industrial revolution introduced steam and water into manufacturing and the second electricity and assembly lines, the third saw computers come online. This was towards the end of the 1960s and the biggest benefit that computer software brought to manufacturing was automation, which increased the speed and accuracy of how things were made. The fourth industrial revolution builds on this and enhances it with smart and autonomous systems fuelled by data.
Smart move
While Industry 4.0. has become the generic term (it was originally coined back in 2011 by Working Group members in Germany as the ‘computerisation across industries for the next industrial revolution’) there are a number of terms to describe it including Industrial Internet of Things (IIoT), smart factories, smart manufacturing, digitalising manufacturing, and the list goes on. The prefix ‘smart’ implies intelligence, meaning that all elements of the factory are equipped with integrated computing power and digital technologies that allows for connectivity, intelligent automation and data exchange.
This revolution seems to be happening at pace with many larger companies adopting the computing power and digital technologies to transform their facilities into smart facilities. According to a study carried out by McKinsey, these companies are referred to as lighthouses. As stated in the report, “Lighthouses are leading-edge manufacturing sites implementing technologies of the Fourth Industrial Revolution to generate compelling financial, operational, and environmental returns. Our first takeaway from our lighthouse research is that digital is no longer optional. If you look across these lighthouse organisations and across the world, we see that lighthouses have been more successful in adapting to the challenges posed by COVID-19 and capturing the opportunities related to the pandemic.”
However, many companies, particularly SMEs, have yet to take the first step on their digital manufacturing journey and implement these digital technologies into their production processes. Despite being encouraged to do so in order to reap the benefits of increased productivity, agility and competitiveness, the question is where do they start and what will it mean for their business?
The technologies driving Industry 4.0.
There are a range of digital technologies driving Industry 4.0. These include artificial intelligence (AI), virtual reality (VR) and augmented reality (AR), sensors, robotics, edge computing, additive manufacturing, digital twins, cloud computing, low latency connectivity, services platforms and APIs, blockchain and cybersecurity, amongst others.
Artificial intelligence (AI)
Virtual reality (VR)
Augmented reality (AR)
These technologies are all data-driven and while we’ve often heard the term ‘big data’ it’s not the amount of data that’s important - merely gathering data for data’s sake - it’s what is being done with it that is. Through analytics, companies are able to gain valuable insights from this data. But when adding AI or machine learning into the mix, things really start to get interesting.
Essentially, AI has the ability to convert real-time data into actionable insights to enable machines to act ‘intelligently’. With computing technology at the point where it is now, AI and machine learning solutions can ‘learn’ from data and make decisions with minimal human intervention and without being explicitly programmed, and this is all done at speed.
The promise is that these digital technologies, which allow for the enhanced collection and analysis of this all important data, will lead to a number of benefits including: fostering innovation, increased productivity, environmental sustainability, competitive advantage, increased reliability, efficiency and flexibility. And although these technologies can be used standalone, the true benefits are reaped when used in combination with one another.
HoloLens from Microsoft – “The ultimate mixed reality device”
Industry 4.0. use cases
There are examples of Industry 4.0 in every sector. An obvious one is manufacturing as this is the sector people immediately think of when talking about industrial revolutions. In a smart manufacturing environment, machines, equipment and devices are connected through a factory network providing manufacturers with real-time data of what is going on in their production line at any time, which ultimately helps improve decision making.
Smart manufacturing – the connected factory in action. Belden
Bringing a digital technology such as AI into this setting can lead to a number of benefits. A report published by the Capgemini Research Institute entitled ‘Scaling AI in manufacturing operations: A practitioners’ perspective’ identifies three AI use cases that are the most likely to help manufacturers kickstart their AI journey as they offer clear business value, can be most easily implemented and would deliver the best return-on-investment.
The first is preventative or intelligent machine maintenance: using data from sensors on machinery and equipment the technology can predict potential problems and identify when parts need to be replaced. The second is product quality inspection: through the utilisation of high resolution cameras and powerful image recognition technology real time in-line inspection can be carried out. The third is demand planning and forecasting: using machine learning manufacturers can predict changes in consumer demand and behaviours, which then enables them to make the necessary adjustments to production schedules leading to more accurate forecasts.
In the agriculture industry, Industry 4.0 is known as Agriculture 4.0 or smart farming. There are a number of applications for digital technologies such as AI and robotics within farming. A key driver for adopting them is to drive efficiencies especially when considering that, according to the Food and Agriculture Organisation (FAO) and World Bank, the global population will reach almost 10 billion people by 2050. It is currently 7.6 billion.
There are companies already bringing connected, digital devices to market such as the Small Robot Company (SRC), a British agritech start-up for sustainable farming, which recently announced the launch of its first commercial robot, ‘Tom’. During technology demos at the Lockerley Estate, Hampshire, SRC demonstrated Tom’s new plant weeding capabilities. Working in concert with its artificial intelligence Advice Engine ‘Wilma’, Tom is able to identify and kill individual weeds with electricity. SRC has also developed other farmbots - together with Tom there is Dick and Harry, and together these bots will plant, monitor and treat arable crops autonomously, with minimal waste.
‘Tom’ and ‘Dick’, working in concert with its artificial intelligence Advice Engine ‘Wilma’ to identify and kill individual weeds with electricity.
Likewise, in the healthcare industry there are many applications for Industry 4.0, some of which are already on the market. These digital health technologies were given a boost during the pandemic with patients and healthcare practitioners relying on solutions for telemedicine and teleconsultation, remote monitoring, connected devices, digital health platforms and health apps.
These solutions will become increasingly efficient with the use of AI and machine learning. For instance, Google's Cloud Healthcare application programming interface (API) includes AI solutions that will help physicians make more informed clinical decisions regarding patients. AI used in Google Cloud takes data from users' electronic health records through machine learning – creating insights for healthcare providers to make better clinical decisions.
Google Cloud Healthcare API
Lastly, smart buildings is a key industry that is set to greatly benefit from digital technologies. Right from how buildings are designed and built through to using IoT devices to monitor the building’s characteristics, analyse the data, and generate insights around usage patterns and trends that can be used to optimise the building’s environment and operations. Pd-m recently worked on such a product. Start-up Flow Technologies came up with an idea for a real-time footfall device that would allow businesses, for instance gyms and barbers, to track their live occupancy. This means that during quieter times these businesses can let their customers know via an app that they are quiet and so encouraging them to visit. Having helped with the design and development of the prototype sensors as well as the installation methods and user experience, the sensors are currently being trialled.
Start the journey
While Industry 4.0 and what it will enable companies and technologists to do all sounds extremely positive and beneficial, there are obviously challenges to implementing digital technologies. These include investing in the right infrastructure to cope with it. The need to upskill the current workforce to take on new work responsibilities made possible by Industry 4.0 or to recruit new employees with the right skills. Then, of course, a key challenge posed by new digital and data-driven technologies, and a major concern for many, is around privacy and security.
While Industry 4.0 is still evolving and these challenges are being addressed, the fact is that it’s here now. Companies that have adopted it are realising its potential and reaping the benefits. To avoid being left behind completely, it’s time to start taking those initial steps on your digitalisation journey. Research and educate yourself so as to understand what is out there and what is relevant to your business. Like with many things in life: start small but the important thing is to start.