Welcome

Agenda

1. Industrial revolutions
2. Industry 4.0 – History
3. Industry 4.0 – Design principles
4. Industry 4.0 – Components
5. Industry 4.0 – Global readiness
6. Industry 4.0 - Indian automotive sector
7. Conclusion
Industrial revolutions

Marked by a transition from hand production methods to

machines through the use of steam power and water
power.

Its effects had consequences on textile manufacturing,

which was first to adopt such changes, as well as iron
industry, agriculture, and mining
1760 - 1840
Europe / United States

Steam Engine Cotton Gin Sewing Machine

Industrial revolutions

Known as the Technological Revolution, that resulted

from installations of extensive railroad and telegraph
networks, which allowed for faster transfer of people and
ideas.
Increasing electrification allowed for factories to develop
the modern production line. It was a period of great
1871 - 1914
economic growth, with an increase in productivity.

Electricity Mass production Machine tools Telegraphs

Industrial revolutions

Known as the Digital Revolution, the production of the Z1

computer was the beginning of more advanced digital
developments.

This continued with the next significant progress in the

development of communication technologies with the
1969
supercomputer.

Computers Robots Telecommunication

Industry 4.0 – What does it mean?

Industry 4.0 refers to the transformation of industry through

the intelligent networking of machines and processes with the
help of information and communication technology (ICT).

This means that machines will operate independently, or

cooperate with humans in creating a customer-oriented
Now
production field that constantly works on maintaining itself.
Industry 4.0 – Where does it come from?

Term Industry 4.0 was first publicly introduced in 2011

Group of representatives from different fields (such as

business, politics, and academia) under an initiative to
enhance the German competitiveness in the manufacturing
industry.

Now The German federal government adopted the idea in its High-
Tech Strategy for 2020. Subsequently, a Working Group was
formed to further advise on the implementation of Industry
4.0.
Industry 4.0 – What is the idea?

To exploit the potentials of new technologies and concepts

 Availability and use of the internet and IoT
 Integration of technical processes and business processes
in the companies
 Digital mapping and virtualization of the real world
 Smart means of industrial production and products
Now
Industry 4.0 – Benefits?

Industry 4.0 factory could result in

Manufacturing Increase in
cost reduction equipment utilization

Now Increase in sale value

of production

Reduction in Quality Logistics cost

management cost reduction
Industry 4.0 – Other advantages?

 Shorter time-to-market for the new products

 Improved customer responsiveness
 Enabling a custom mass production without significantly
increasing overall production costs
 More flexible and friendlier working environment
 More efficient use of natural resources and energy
Now
Industry 4.0 – Important terminology

Cyber-physical systems - are seen as the basis and enablers of

new capabilities such as ‘condition monitoring’, ‘remote
control/monitoring’ and ‘track and trace’.

Examples of cyber-physical systems are smart machines and

production facilities which are capable of autonomously
Now
exchanging information, triggering actions and controlling
each other. The capabilities they offer are the enablers of
‘smart factories’.
Industry 4.0 – What are the design principles?

Four design principles of Industry 4.0 enable identifying and realizing

applications in industrial transformation. The design principles are:

1. Interconnection - ability of machines, devices, sensors, and people to

connect and communicate with each other via the Internet of things
(IoT)

Now
Industry 4.0 – What are the design principles?

Four design principles of Industry 4.0 enable identifying and realizing

applications in industrial transformation. The design principles are:

2. Information transparency - Provides operators with comprehensive

information to inform decisions. Inter-connectivity allows operators to
collect immense amounts of data and information from all points in the

Now manufacturing process.

Industry 4.0 – What are the design principles?

Four design principles of Industry 4.0 enable identifying and realizing

applications in industrial transformation. The design principles are:

3. Technical assistance - Technological facility of systems to assist

humans in decision-making and problem-solving, and the ability to help
humans with difficult or unsafe tasks

Now
Industry 4.0 – What are the design principles?

Four design principles of Industry 4.0 enable identifying and realizing

applications in industrial transformation. The design principles are:

4. Decentralized decision - ability of cyber physical systems to make

decisions on their own and to perform their tasks as autonomously as
possible.

Now
Manufacturing Automation Evolution

 Mechanization
 Established process control
 Manual data collection
 Manual decision making
Manufacturing Automation Evolution

 Automation
 Statistical Process Control
 Automatic data collection
 Manual decision making
Manufacturing Automation Evolution

 Connected machines
 Information transparency
 Big data
 Decentralized decision – no
human intervention
Industry 4.0 - Components

Internet of Things (IoT) - a concept that refers to

connections between physical objects like sensors
or machines and the Internet

Industrial Internet of Things (IIoT) - a concept

that refers to the connections between people,
data, and machines as they relate to
manufacturing.
Industry 4.0 - Components

Autonomous robots - will interact with each

other and humans. Because the technology is
expensive, and the capacities of autonomous
robots are still rather limited

M2M - stands for machine-to-machine, and refers

to the communication that happens between two
separate machines through wireless or wired
networks

System Integration - Many systems are highly

automated within their own operation, but
struggle to commu­nicate with other systems.
Defining common languages for data exchange 
Industry 4.0 - Components

Simulation: Allows for different scenarios to be

assessed. Once systems are assessed, cost-
effective solutions can be developed, tested, and
implemented much faster, ultimately leading to
reduced costs and time to market.

How?
Digitization: Digitization refers to the process of
collecting and converting different types of
information into a digital format

Digital twin / Virtual production: Define program

parameters, teach components, generate setup
and pick lists, calculate throughput times, and
optimize entire production processes
Industry 4.0 - Components

Big data - Big data refers to large sets of

structured or unstructured data that can be
compiled, stored, organized, and analysed to
reveal patterns, trends, associations, and
opportunities

What?
Real-time data processing: Real-time data
processing refers to the abilities of computer
systems and machines to continuously and
automatically process data and provide real-time
or near-time outputs and insights.
Industry 4.0 - Components

Big data - Big data refers to large sets of

structured or unstructured data that can be
compiled, stored, organized, and analysed to
reveal patterns, trends, associations, and
opportunities

Where?
Cloud computing: Cloud computing refers to the
practice of using interconnected remote servers
hosted on the Internet to store, manage, and
process information.
Industry 4.0 - Components

Big data - Big data refers to large sets of

structured or unstructured data that can be
compiled, stored, organized, and analysed to
reveal patterns, trends, associations, and
opportunities

Why?
Artificial intelligence (AI): Artificial intelligence is a
concept that refers to a computer’s ability to
perform tasks and make decisions that would
historically require some level of human
intelligence.
Industry 4.0 - Components

Big data - Big data refers to large sets of

structured or unstructured data that can be
compiled, stored, organized, and analysed to
reveal patterns, trends, associations, and
opportunities

How?
Machine learning: Machine learning refers to the
ability that computers have to learn and improve
on their own through artificial intelligence—
without being explicitly told or programmed to do
so
Industry 4.0 - Components
Industry 4.0 - Components

3D Printing: Also known as additive

manufacturing is the process of building an object
by depositing material in multiple layers

And because additive technology can be done on

demand, production time for those customized
products is also significantly shorter
Industry 4.0 - Components

Augmented Reality: provides real-time

information in an effective manner to allow
humans to better integrate and interact with
electronic systems
Industry 4.0 - Components

Cyber security: As we move away from closed

systems (with the increased connectivity from the
IoT and Cloud), the security of information
becomes paramount.

Security and reliability enable the successful

implementa­tion of a truly modern and digitized
production workflow, leveraging all of the
benefits of a connected environment.
Industry 4.0 – Y Model
Industry 4.0 – Y Model
Smart factory – Smart product - Logistics

Business process Production process

Industry 4.0 – Global readiness

Networked readiness Index is a key indicator of how countries

are doing in the digital world.

 India’s rank on the Network Readiness Index in 2016 is 91

out of 139 countries.
 At 91, India was ahead of Pakistan (110) and Bangladesh
(112), but behind Sri Lanka (63), Malaysia (31), and China
(59).
 Singapore topped the rankings for second year in a row.
 The US is placed at 5th position.
Industry 4.0 – Six dimensional model

German Engineering Federation (VDMA) has coined a six

dimensional model to assess the readiness of the enterprises
As per the current understanding of Industry 4.0 the readiness
of the enterprises can be assessed on the below mentioned six
dimensions
Industry 4.0 – Six dimensional model

• Level 0 is the outsiders – those companies that have done nothing

or very little to plan or implement Industry 4.0 activities
• Level 5 describes the top performers – those companies that have
successfully implemented all Industry 4.0 activities
Industry 4.0 – Indian Automotive Sector

 India has now been ranked sixth among the world’s 10 largest
manufacturing countries.
 By 2026, India is expected to be the third largest automotive market
by volume in the world
 Global car majors have been ramping up investments in India to
cater to growing domestic demand
Industry 4.0 – Indian Automotive Sector

The Indian automotive industry has also taken some notable steps
towards industry 4.0
• Bajaj Auto was one of the first automotive enterprises to
initiate automation in the industry. It commenced the process
of automation in 2010, today it uses 100-120 Collaborative
Robots in its production facilities.
• Maruti Suzuki manages 7 process shops and 5 assembly lines
by around 1,700 robots
Industry 4.0 – Indian Automotive Sector

The Indian automotive industry has also taken some notable steps
towards industry 4.0
• Ford has managed to operate the assembly lines and body
shop of its Sanand Plant by 437 robots
• Hyundai has also taken steps to minimise its labour cost by
utilising over 400 robots in Sriperumbudur Plant
• The production lines of TATA consist of over 100 robots in the
Sanand Plant
Industry 4.0 – Conclusion

• Industry 4.0 will revolutionise manufacturing around the globe,

as did the first three industrial revolutions
• This revolution will be vastly different from the previous ones
• It will highlight the fact that small changes in one area of the
manufacturing ecosystem will create significant ripples
throughout the ecosystem, due to connectivity throughout the
supply chain and the speed at which information propagates
• It is clear that Industry 4.0 presents tremendous
opportunities, and this fact highlights the need for a highly
trained and flexible workforce and production capacity that
can answer the needs of tomorrow as well as those of today.
Questions?
Thank you