How does Smart Industry work, and what technologies does it use?

With its unprecedented speed and scale, the fourth industrial revolution, which we now live in, allows companies to improve operations by using a data driven approach. In our last article, we discussed in detail what Industry 4.0, also known as Smart Industry, entails. In this article, we will look at how it works and what technologies it uses. 

As mentioned above, Industry 4.0 helps to improve the operations of companies through a data driven approach. By leveraging the data generated by the manufacturing assets, companies are enabled to make smarter - data driven - decisions. Technologies like Internet of Things (IoT), 5G, and data analytics help generate the data and uncover relevant insights. These insights can prove to be vital keys to operational resilience despite current global manufacturing disruptions (EMnify, n.d.).

Industry 4.0 revolutionizes manufacturing

Companies are revolutionizing their manufacturing, and supply chain processes with the implementation of Smart Industry. In their production facilities and throughout their operations, manufacturers are integrating new technologies, such as Internet of Things, artificial intelligence, machine learning, cloud computing, and augmented reality. 

Advanced sensors, custom software and robotics support smart factories with both the collection and real-time analysis of data to enable better decision making. Even more business value can be generated if data from the manufacturing process is combined with the data from ERP, supply chain, and other enterprise systems to make previously siloed data accessible and actionable.

The benefits of these digital technologies include an increased level of automation within the entire company, the possibility for both predicitve- and prescriptive maintenance, self-optimization of manufacturing processes, and above all, a new level of agility to customize products (and thus production lines) based on the customers demand. 

With the implementation of Industry 4.0 in manufacturing facilities, it brings a huge opportunity to increase competitiveness and profitability.

For example, the analysis of big data, collected from all levels of the company, from ERP systems, to production operations, ensures real-time insights on manufacturing assets. This will then be the basis for the implementation of prescriptive maintenance, to minimize (unplanned) equipment downtime and increase production throughput. 

Another example to increase productivity and improve quality in a production facility is by using Industrial IoT devices. By replacing manual inspection with AI-enabled visual insights, based on the IoT devices, manufacturing errors can be reduced and resources will be saved. A smartphone connected to the cloud can be set up with minimal investment for personnel to monitor manufacturing or supply chain processes from virtually anywhere. 

Technologies and concepts related to Smart Industry can be applied across all types of (industrial) companies and processes. Among others, it is applicable to production processes, operations processes, and supply chain processes, including discrete and process manufacturing.

Smart Industry technologies

Some of the core concepts and technologies that enable Industry 4.0 through it’s design principle are: 

Industrial Internet of Things (IIot)

Internet of Things refers to billions of physical devices around the world that are all connected to the internet, collecting and sharing data with their users. Smart manufacturing relies heavily on the Internet of Things. Manufacturing assets are equipped with sensors that generate and transmit data to the company's database. Through this connectivity, large amounts of data can be collected, analyzed, and exchanged. 

Augmented reality

Augmented reality (AR) applications in Smart Industry support technicians and engineers in their working environment. AR glasses support the vision of the user with other data sources. Imagine looking at a wall and seeing the electrical wiring behind it, that’s the kind of support Augmented reality can provide. With the help of this technology, users can get visual instruction from remote experts to maintain or repair a specific machine. 

Artificial Intelligence and Machine Learning

By using Artificial Intelligence and Machine Learning, (industrial) companies are enabled to take full advantage of generated information, within a company. Not just production process or machine information, but also information across business units, from supply chains or ERP systems. Artificial Intelligence and Machine Learning can provide insights into operations and business processes, enabling visibility, transparency, predictability, and automation. Both Machine Learning and Artificial Intelligence can for example be used to learn healthy machine behavior, and generate a notification if the behavior starts to deviate, long before an operator will ever notice it. 

Cloud computing

Another key component of a successful Industry 4.0 strategy is cloud computing. Through cloud computing, IT resources like data storage and computing power, necessary for for example big data analytics, are available on demand. Meaning that manufacturing companies do not have to invest in expensive servers, and other IT hardware.

Edge computing

As a result of real-time production operations, some data must be done on the “edge” - also known as the location where the data is created - to facilitate instant data analysis. As an example, if a safety issue were to arise, the time needed to send data to the enterprise's database, analyze it, and send the results back, may be too lengthy to mitigate the issue. For this type of application, edge computing can provide an outcome. 

Digital twin

A digital twin is a replica of a process, machine, production line, supply chain, or even entire manufacturing facility. Digital twins are supplied with data generated by IoT sensors, PLC, and other data sources, and are used to help increase productivity, simulate new workflows, or even design new production processes. By simulating a digital twin, manufacturing facilities can test changes in a process to improve capacity, or to improve product quality. 

How to get started with Smart Industry

In the following article, we will elaborate on a step-by-step approach on how to get started with Smart Industry. In our previous article, you can read more about what Smart Industry actually is, and why it is important.

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Credits main image: Industrial revolution vector created by jcomp