INDUSTRY 4.0 : IMPRESSIONS, INSIGHTS &

IMPLICATIONS

S G DESHMUKH

ABV-INDIAN INSTITUTE OF INFORMATION TECHNOLOGY & MANAGEMENT,

GWALIOR

National Conference on Advances in Mechanical Engineering (NCAME - 2016).

B.S. Anangpuria Institute of Technology and Management12 MARCH 2016

Key talking points ..

• What is mechanical engineering?

• Today’s manufacturing – need /imperative

• Impressions• Connected world• Device vis-à-vis human being• Service oriented architecture

• Insights

• Various implications• Manufacturing & control• Maintenance• Workforce

Where is Mechanical Engineering?

• Its presence?• Its form?• Its content?• Relationship with other disciplines?

• Mechanical engineering is the discipline that applies the principlesof engineering, physics, and materials science for the design, analysis,manufacturing, and maintenance of mechanical systems. It is the branchof engineering that involves the design, production, and operation ofmachinery.

• Source: https://en.wikipedia.org/wiki/Mechanical_engineering

What are the Advances in

Mechanical Engineering ?

• Theme of the conference !• Mechanical Design• Manufacturing Sciences & IE• Thermo-fluids

Mechanical Engineering advanced by the developments in other engineering

Let us get back into History !!

Evolution ..

First Industrial

revolutionIntroducing mechanical

production machines

powered by water and

steam/ Mechanization

Second Industrial

revolution Introducing mass

production

lines powered by

electric

energy

Third industrial

revolution Through the use of

electronics

and IT further

progression in

autonomous production

Fourth Industrial

revolutionBased on cyber-

physical-

Systems

Mass customization ?

Steam Power/Mechanical Energy

Electrical Energy ICT ? IOT

End of 18th Century Start of 20th Century Early 70’s 2012-

Let us get into present:

Smart regime..

SmartPhones

Smart Homes

Smart Vehicles

Smart factory

Smart City

Technology Push

Market Pull

Observations..

• Today’s customer- Hyper-demanding

• Today's world : Hyper-connected

• Today’s manufacturing- Hyper- Smart and Sustainable

• Internet of Things (IoT) : Network of physical objects—devices, vehicles, buildings and other items embedded with electronics, software, sensors, and network connectivity—that enables these objects to collect and exchange data.

source-https://en.wikipedia.org/wiki/Internet_of_Things

Insights ..1..

•Manufacturing – wealth generator

•Across the globe, governments, industrial federations, and corporations have recognized the significance of creating their own added value through production.

•One cant compete unless manufacturing is strong !

•Why “Make in India”?

Impression 1:

Ubiquitous Information Availability

• Global markets are demanding more flexibility and productivity

• Resource consumption has to be minimized.

• Progress in in communication, sensor and production technologies opens new sustainable and competitive ways of innovation, production and consumption

• More and faster information will optimize resource use, shorten lead times, increase productivity and allow the automated production of smart products

• Information in any form, any time, any device

Insights ..2..

• “Information that drives the next century’s structural shift in manufacturing.”

• Making real-time information available:• when it is needed,

• where it is needed

• and in the form it is needed throughout the Manufacturingecosystem

What is Industry 4.0

Synergistic combination of industry and the current Internet of Things (IoT) technology is Industry 4.0

An initiative for Smart Manufacturing !

Industry perspective ..

Industry 4.0 :

Challenges & solutions:

• Status paper by Deloitte (2014) • http://www2.deloitte.com/content/dam/Deloitte/

ch/Documents/manufacturing/ch-en-

manufacturing-industry-4-0-241

Disruptive technologies behind

Industry 4.0

• Analytics and Big Data

• Mobile technology

• AI & Robotics

• Cloud Computing

• Social networking

The traditional Factory

• Monolithic

• Hard wired

• Centralized

• Fixed locations

• Low skill set for labor

Smart factory ..at the heart of

Industry 4.0

• Smart Manufacturing Intelligence• Understanding of the manufacturing process through modeling and analysis

• Ability and agility to observe and take action on integrated patterns of operation through networked data, information, analytics, and metrics

• Dynamic management of energy and material resources

• Smart Manufacturing Practice • Generating and coordinating use of sensor-based, data-driven manufacturing intelligence

• Applying integrated performance metrics based on real-time action

• Reusing, and scaling integrated practice using a common infrastructure (both cyber and physical)

• Smart Manufacturing Execution • Dynamic coordination of decision/action workflows in heterogeneous environments without losing control of state

• across different time constants and seams, including supply chain

• multi-vendor discrete, continuous, operational and human/social applications

• Applications that can share data and data that can share applications and devices

Scheme of things

16

Internet of things

Digitized Production

Smart products Smart factory

…Digitized services

Product innovation

Process innovation

Intelligent systems

Cloud and AI based

networking

Impression 2:

Siemens view of Industry 4.0

• Industry 4.0 is an interesting initiative introduced by German companies such as Siemens with a motive of enhancing German competitiveness in manufacturing.

• http://www.totallyintegratedautomation.com/2014/07/smart-manufacturing-industry-4-0-whats

• https://www.youtube.com/watch?v=HPRURtORnis

Insights ..3..

• New organization of value chains.

• On the one hand through vertical network distribution, product

development and services.

• On the other hand through horizontal network distribution

between supplier, contractor and customer.

• Value chains generate hybrid products (Part material part

service part knowledge)

• Manufacturing : Service orientation ?18

Implications ..1..

Various connotations

• Smart materials

• Smart Controls

• Smart manufacturing processes

• Environment friendly operations

• Closer to customer and pulled by smart customer trigger

Implications ..2..

Change in orientation

• From compartmentalized to interdisciplinary mode

• From pure manufacturing to service +Manufacturing

• From producer to customer

• From push to pull

• From Reactive to Responsive

Implications ..3..

Networking

• It presents a big opportunity to have an enterprise view of suppliers, distributors and companies in the entire value chain where there will be a strong degree of coupling between Cyber and Physical world!.

• The entire manufacturing facility can be visualized and controlled through apps available on smart devices!- remotely controlled yet at the ground level .

• Benefits : Reduction in manufacturing cycle time and at the same time, the vision is to have mass customization affordable with intimate knowledge about customer!.

• The manufacturing will be smart, social and sustainable !

Implications ..4..

Manufacturing & Engineering

Manufacturing

• Replacing repettitive/dull monolitic human work in a drastic manner • Synegistsic man-machine collaboration in real time • Conectiviuty of devices/human • Technology : 3D – Printing/Virtual Reality (training / support )• Remote control of production equipment

Engineering

• Virtul reality : Computer based simulation, gaming • AI support aided by social networking • Technology platform: cloud-computing and crowd-sourcing• Innovation & Creativity based

22

Implications ..5..

Maintenance & Manufacturing control

Maintenance Remote controlled maintenance Designed for maintenance Wen enabled support for decision making Technology support: Exensive use of sensors to monitor the state of

equipmentManufactirng control Integrated approach Seamless/ paperless logistics Tractability / traceability of products and parts- RFID Digital memory of the product Optimisation of production with BIG DATA/Analytics Social media 23

Implications ..6..

Quality of workforce

• Rapid change of necessary skills/capabilties

• Creation of new jobs for high skilled workers in the areas of planning, configuration and maintenance of the new technologies

• Expansion of low-skilled work through the use of robots and assisting systems

• Ergonomical improvement through the use of robots

• Extensive control and monitoring of workers behavior and performance

• Increased expections regarding individual flexibility

24

Implications ..7..

For educational institutes

• Institutes must develop strong linkages with industry to understand and appreciate and gear themselves for meaningful R&D in collaboration with industry

• The discipline boundaries such as electrical, mechanical etc must vanish so as to appreciate and understand integrated solutions as desired by the industry

• Digital manufacturing is going to revolutionize our view of manufacturing and consequent need to develop trained manpower for the same. This calls for strong curriculum review.

• Mechanisms to upgrade skills need to be established in conjunction with industry. Online courses forums such as Mooc, need to be aggressively utilized.

Industry 4.0 in summarized form

• Digitalization and increased integration

» The horizontal value chain and vertical connectivity of a company

• Autonomous, self-organizing production units

• Intelligent products actively support the production process

• Creation of innovative business models

• Industry 4.0 provides the framework

My post on Linkedin about industry 4.0

• https://www.linkedin.com/pulse/industry-40-implications-technical-institutes-sanjeev-deshmukh?trk=pulse_spock-articles

Where is Mechanical Engineering?

• Its presence? Everywhere !!

• Its form? Is embedded into others !!

• Its content? Both digital and analogue and SMART !

• Relationship with other disciplines? Interdisciplinary and cutting across boundaries

SMART..

• Sustainable

• Meaningful

• Achievable

• Relevant

• Tractable

• “Smart ’ - Investments in human and social capital and traditional Physical and modern IT infrastructure is done with a wise management of natural resources to add value

Industry 4.0 on youtube

• Industry 4.0- Integrated industry reaches the next level (4.01 minutes )

• https://www.youtube.com/watch?v=ccB6e18VwsQ

• Furniture production on the way to Industry 4.0 (3.53 minutes)

• https://www.youtube.com/watch?v=KUKl-c5uWbM

• Industry 4.0 in the Volkswagen group (5.12 minutes)

• https://www.youtube.com/watch?v=JTl8w6yAjds

Code-n-Conference on Industry 4.0

• Industry 4.0 : Tapping the full potential of future manufacturing ( Hour 25 minutes) – Proceedings of the conference

• https://www.youtube.com/watch?v=wxO7NOWF39o

Acknowledgement

• Dr Kota Harinarayana (Chairman, BOG, IIITDM Jabalpur)

• Mr Baba Kalyani (CMD, Bharat Forge )

• Prof Puneet Tondon (IIITDM, Jabalpur)

• Mr Ashutosh Chinchalkar (CMD, Smart Controls, Gwalior)

• My special thanks to Prof Lajpat Rai, and Prof JP Subrahmanyam

Thank you deshmukh.sg@gmail.com