Technologies are Driving Industry 4.0
Industry 4.0 is revolutionising the way companies manufacture, improve, and distribute their products. Manufacturers are integrating new technologies, including the Internet of Things (IoT), cloud computing and analytics, and AI and machine learning, into their production facilities and throughout their operations.
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 mechanisation and connectivity make it possible for large amounts of valuable data to be collected, analysed, and exchanged.
Cloud computing is a cornerstone of any Industry 4.0 strategy. Full realisation of smart manufacturing demands connectivity and integration of engineering, supply chain, production, sales and distribution, and service. The cloud helps make that possible. In addition, the typically large amount of data being stored and analysed can be processed more efficiently and cost-effectively in the 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.
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 that provide 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.
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 minimises 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.
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 cybersecurity approach that encompasses IT and OT equipment.
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 minimise downtime or improve capacity.
