ASSIGNMENT

ON
INDUSTRY 4.0

Date of Submission: 22nd April 2022

Submitted To, Submitted By,

Prof. Dr. Siby James Shefin TomShaji

Dept. Of Management Studies S4 MBA – A Batch

Mangalam College of Engineering Mangalam College

of Engineering
 INDUSTRY 4.0

Industry 4.0 refers to a new phase in the Industrial Revolution that focuses
heavily on interconnectivity, automation, machine learning, and real-time
data. Industry 4.0, which encompasses IIoT and smart manufacturing,
marries physical production and operations with smart digital technology,
machine learning, and big data to create a more holistic and better-connected
ecosystem for companies that focus on manufacturing and supply chain
management. While every company and organization operating today is
different, they all face a common challenge—the need for connectedness and
access to real-time insights across processes, partners, products, and people.

Industry 4.0 isn’t just about investing in new technology and tools to improve
manufacturing efficiency—it’s about revolutionizing the way your entire
business operates and grows.
 Evolution of Industry from 1.0 to 4.0
Before digging too much deeper into the what, why, and how of Industry 4.0, it’s
beneficial to first understand how exactly manufacturing has evolved since the
1800s. There are four distinct industrial revolutions that the world either has
experienced or continues to experience today.

The First Industrial Revolution

The first industrial revolution happened between the late 1700s and early 1800s.
During this period of time, manufacturing evolved from focusing on manual labour
performed by people and aided by work animals to a more optimized form of
labour performed by people through the use of water and steam-powered engines
and other types of machine tools.

The Second Industrial Revolution

In the early part of the 20th century, the world entered a second industrial
revolution with the introduction of steel and use of electricity in factories. The
introduction of electricity enabled manufacturers to increase efficiency and helped
make factory machinery more mobile. It was during this phase that mass
production concepts like the assembly line were introduced as a way to boost
productivity.

The Third Industrial Revolution

Starting in the late 1950s, a third industrial revolution slowly began to emerge, as
manufacturers began incorporating more electronic—and eventually computer—
technology into their factories. During this period, manufacturers began
experiencing a shift that put less emphasis on analogue and mechanical technology
and more on digital technology and automation software.

The Fourth Industrial Revolution, or Industry 4.0

In the past few decades, a fourth industrial revolution has emerged, known as
Industry 4.0. Industry 4.0 takes the emphasis on digital technology from recent
decades to a whole new level with the help of interconnectivity through the
Internet of Things (IoT), access to real-time data, and the introduction of cyber-
physical systems. Industry 4.0 offers a more comprehensive, interlinked, and
holistic approach to manufacturing. It connects physical with digital, and allows
for better collaboration and access across departments, partners, vendors, product,
and people.Industry 4.0 empowers business owners to better control and
understand every aspect of their operation, and allows them to leverage instant data
to boost productivity, improve processes, and drive growth.

Industry 4.0 Technologies

These innovations bridge the physical and digital worlds and make smart and
autonomous systems possible. Businesses and supply chains already use some of
these advanced technologies, but the full potential of Industry 4.0 comes to life
when they’re used together.

Big Data and AI analytics:

In Industry 4.0, Big Data is collected from a wide range of sources, from factory
equipment and Internet of Things (IoT) devices, to ERP and CRM systems, to
weather and traffic apps. Analytics powered by artificial intelligence (AI) and
machine learning are applied to the data in real time – and insights are leveraged to
improve decision-making and automation in every area of supply chain
management: supply chain planning, logistics management, manufacturing, R&D
and engineering, enterprise asset management (EAM), and procurement.

Horizontal and Vertical integration:

The backbone of Industry 4.0 is horizontal and vertical integration. With horizontal
integration, processes are tightly integrated at the “field level” – on the production
floor, across multiple production facilities, and across the entire supply chain. With
vertical integration, all the layers of an organization are tied together – and data
flows freely from the shop floor to the top floor and back down again. In other
words, production is tightly integrated with business processes like R&D, quality
assurance, sales and marketing, and other departments – and data and knowledge
silos are a thing of the past.

Cloud Computing:

Cloud computing is the “great enabler” of Industry 4.0 and digital transformation.
Today’s cloud technology goes way beyond speed, scalability, storage, and cost
efficiencies. It provides the foundation for most advanced technologies – from AI
and machine learning to the Internet of Things – and gives businesses the means to
innovate. The data that fuels Industry 4.0 technologies resides in the cloud, and the
cyber-physical systems at the core of Industry 4.0 use the cloud to communicate
and coordinate.

Augmented Reality (AR):

Augmented reality, which overlays digital content on a real environment, is a core

concept of Industry 4.0. With an AR system, employees use smart glasses or
mobile devices to visualize real-time IoT data, digitized parts, repair or assembly
instructions, training content, and more when looking at a physical thing – like a
piece of equipment or a product. AR is still emerging but has major implications
for maintenance, service, and quality assurance as well as technician training and
safety.

Industrial Internet of Things (IIoT):

The Internet of Things (IoT) – more specifically, the Industrial Internet of Things –
is so central to Industry 4.0 that the two terms are often used interchangeably. Most
physical things in Industry 4.0 – devices, robots, machinery, equipment, products –
use sensors and RFID tags to provide real-time data about their condition,
performance, or location. This technology lets companies run smoother supply
chains, rapidly design and modify products, prevent equipment downtime, stay on
top of consumer preferences, track products and inventory, and much more.

Additive manufacturing/3D printing:

Additive manufacturing, or 3D printing, is another key technology driving Industry

4.0. 3D printing was initially used to as a rapid prototyping tool but now offers a
broader range of applications, from mass customization to distributed
manufacturing. With 3D printing, for example, parts and products can be stored as
design files in virtual inventories and printed on demand at the point of need –
reducing both transportation distances and costs.

Autonomous robots:

With Industry 4.0, a new generation of autonomous robots is emerging.

Programmed to perform tasks with minimal human intervention, autonomous
robots vary greatly in size and function, from inventory scanning drones to
autonomous mobile robots for pick and place operations. Equipped with cutting-
edge software, AI, sensors, and machine vision, these robots are capable of
performing difficult and delicate tasks – and can recognize, analyze, and act on
information they receive from their surroundings.

Simulation/digital twins:

A digital twin is a virtual simulation of a real-world machine, product, process, or

system based on IoT sensor data. This core component of Industry 4.0 allows
businesses to better understand, analyze, and improve the performance and
maintenance of industrial systems and products. An asset operator, for example,
can use a digital twin to identify a specific malfunctioning part, predict potential
issues, and improve uptime.

Cybersecurity:

With the increased connectivity and use of Big Data in Industry 4.0, effective
cybersecurity is paramount. By implementing a Zero Trust architecture and
technologies like machine learning and block chain, companies can automate threat
detection, prevention, and response – and minimize the risk of data breaches and
production delays across their networks.

Benefits of Industry 4.0

Increased Efficiency in Production

With increased automation and capacity for continuous improvement, smart

factories will be able to increase their efficiency to levels previously thought
impossible. Every resource will be optimized automatically for minimum wastage.

More Potential for Innovation

Industry 4.0 is all about innovation. Through data gathered from connected devices
such as the Internet of Things, design teams will know what works and what
doesn’t. This data will fuel their innovation for new and improved products and
systems.

Accelerated Response to Customer Needs

Customer needs are changing faster than many industries can keep up with. They
want new designs, new technology, and new features every few months. Industry
4.0 is built for agility so that you can respond to market dynamics faster than the
competition.

Reduced Costs and Higher Profit Margins

You will achieve lower operating costs overall through better uses of resources,
less wastage, reduced quality issues, and less downtime. Despite a large initial
investment, you will have significantly higher profit margins to enable you to get
an ROI within a few years.

Quality Assurance

Industry 4.0 gives you the capability to perfect product quality. You will also be
able to assure excellence beyond the factory through product tracking during
delivery. By eliminating that elusive 1% or so of defective products, you can also
keep your costs to a minimum.