Strategic roadmap

for industry
What’s Industry 4.0…??
- Industrial revolutions are characterized by a major shift in the technological
landscape.

- To date, humans have experienced four industrial revolutions.

- The first one came in the form of mechanization,

the second one brought electrical energy,
and the third revolution brought forth the rise of electronics,
telecommunications,
and, of course, computers
The fourth industrial revolution, called Industry 4.0,
stems from its German equivalent ‘Industrie 4.0’ in
2011.
- Industry 4.0 (also referred to as digitization of manufacturing) is characterized
by cyber physical systems, automation, and data exchange.

- Industry 4.0 enabling technologies is a difficult task and becomes even more
challenging without any standardized approach.

- It also provides a strategic roadmap for the implementation of Industry 4.0,

based on lean six sigma approaches i.e
i) interoperability 2 virtualization
ii) virtualization
1 Interoperability
iii) Decentralization
iv) real-time capability service orientation 3
v) service orientation and
vi) modularity. real-time capability
5
4 Decentralization

modularity 6
 1
Interoperability
Interoperability refers to the ability of systems and workforce in a
business to communicate,
exchange data, and coordinate activities

2 virtualization
service orientation 3

4 Decentralization
real-time capability 5
modularity 6
 2 Virtualization

Virtualization is linked to the monitoring of

physical processes either by one virtual
resource from multiple physical resources
or multiple virtual resources from one
physical resource. 1
service orientation
3 Interoperability

real-time capability
5
4 Decentralization

modularity 6
3 Service Orientation

The ability to use big data analytics to

obtain a predictive analysis that can help in
better understanding 2 virtualization
the customers’ needs is referred to as
service orientation. 1

Interoperability

real-time capability
5
4 Decentralization

modularity 6
 4 Decentralization

Decentralization refers to the transition

toward system components rather
than a central system to mitigate risks and 2 virtualization
instill flexibility of operations.
1 Interoperability
service orientation 3

real-time capability
5

modularity 6
 5 Real-time Capability

Real-time capability means the collation and

processing of data in real time that allows
informed and timely decision-making.

2 virtualization

1 Interoperability
service orientation 3

4 Decentralization

modularity 6
 6 Modularity

Modularity refers to the ability of

businesses 2 virtualization
to flexibly adapt to changing
requirements and industry needs
1 Interoperability
service orientation 3

real-time capability
5

4 Decentralization
Opportunities offered by Industry 4.0 enabling
technologies :-
 Industrial Internet of
Additive Manufacturing
Things
Design flexibility, reduced set-up and
tooling time, lightweight and Interconnected systems, production
customized products, less waste, visibility, better inventory managemen
eective for mass production of both safe working environment, reduce
large-scale and small-scale structures machine downtime, increase quality

Augmented Reality Autonomous Robots

Faster and smarter product
Increase efficiency and
development and assembly, enhanced
productivity,
operator performance, expert support
reduce error and re-work, operator
provision, eective machine
safety, exponential learning by
maintenance and quality assurance
collecting and analyzing machine
data
Simulation
Optimize product/process parameters,
reduced investment risk, waste
minimization, allows faster prototyping,
virtual analysis of complex scenarios
 Big Data Analytics Horizontal and Vertical
Integration
Asset/supply chain optimization,
product design/quality, better Optimize supply chain, increase
future differentiation from competition, high
forecasting and identification of productivity, superior product quality,
trends, less waste, reduce set-up costs, errors,
and machine downtime
higher customer satisfactions

Cyber Security

Cloud Computing Protect data and reduce risk of

hacking,
inspires customer confidence,
Low capital costs, flexibility of increase
operations, disaster recovery, automatic productivity, protect against
software updates, increased spyware,
collaboration, freedom of operation, worms, and viruses
data security, opportunities for
upskilling workforce
Phases of the Strategic Industry 4.0
Roadmap:-

- Define
- Measure
- Evaluate
- Optimize
- Develop
- Validate
- Implement
 Define
As per the roadmap, the first phase is to DEFINE the business problem, identify
the limitations of the existing resources, and develop a project scope for the
implementation of Industry 4.0 technologies. This needs to involve both internal
and external stakeholders, i.e., employees, management, shareholders, suppliers,
and customers.

- An appropriate Industry 4.0 transition team should be assembled with

individuals from all sectors of the business, to provide input.

In terms of defining strategies, the assessment of the existing workforce

skillset and future training needs is the next step. Industry 4.0 will not be able to
make a significant difference if it is opposed by the organization’s existing
workforce. Therefore, a change management strategy also needs to be defined,to
allow a smooth transition from the traditional to the digital [-
 Measure

After defining the project, the MEASURE phase is used for data collation.
The purpose of this phase is to clearly understand the customer’s (internal and
external) requirements and develop critical to process and quality attributes
to address those requirements

- This is achieved by dividing the market into different segments, and then
developing measurable critical to process and quality attributes for each
segment using the quality function deployment (QFD) tool.
 Evaluate

- This step analyzes the projected product or service to find

better strategies for attaining the objectives. You must detect the
product and process flaws while analyzing and prototyping the
improved one.
- All stakeholders perform in this stage.
- The production and testing teams evaluate the final product or
service to provide a foundation for improvement.
- Then, the leaders use data to discover process adjustments that
enhance product quality. Finally, the teams decide on the
procedures and make modifications.
 Optimize

- A detailed design is built in this phase that can be subjected to numerical and
statistical analysis to optimize its performance.

- Software packages for CAD design (e.g., Autodesk Inventor), process flow (e.g.,
AnyLogic), and product analysis (e.g., ANSYS) are employed.

- Introducing the concept of lean management is important, as it helps in creating

value to the customer by optimizing resources

- Optimized parameters based on these methodologies should be recorded and used

for developing the new process integrating the technologies of Industry 4.0.

- This stage is crucial, and it is recommended that several optimization approaches

are tested to ensure that every scenario and unexpected variation can be modeled
before the test run.
 Develop

- A detailed plan should be developed for the prototype build, based on the parameters identified
in the previous phase.

- After acquiring all the necessary resources and skilled personnel, the next step
is to identify the most economic method.

- Finally, the prototype manufacturing process flow should be developed according to the
computer simulations, to ensure that they can be validated in the next phase.

- For a manufacturing process, this could mean setting up parallel production lines or using some
machines for this prototype testing and others for the routine production.

- It is important to highlight that the Industry 4.0 implementation should not significantly
disrupt
the normal functionalities of the manufacturing organization and that the prototype should work

in parallel to the day-to-day activities.

 Validate

In this stage, the prototype is tested to validate the simulations.

The reasons for running a pilot include lower risk of failure, assessing true performance in
controlled-but-live experiments, confirming or disproving expected results and relationships, testing
and validating the benefit of the proposed solutions before full-scale implementation.

It is important to highlight that there will always be some difference between the simulated results
and experimental results.

The next step after the pilot run should be the communication of results through different means
and soliciting stakeholder feedback on the outcomes.
 Implement

The successful validation of the prototype manufacturing process should lead to full-scale
implementation.

In this phase, a full-scale pilot is conducted. The pilot is a permanent deployment that delivers
fully on the control plans to monitor the activities involved in the new process.

This phase should be conducted in the same manner as the pilot run but should be adjusted to
accommodate the results of the pilot run.

The barriers to implementation will again be associated with resistance to change

The project team should identify factors favoring/opposing the implementation and recognize
implications, as well as risks, from failing to address the barriers. Once the process design has
been finalized, the implementation should take place.

After the successful implementation of the new process, data should be gathered, the operating
procedures should be documented and standardized for use.
 Conclusion:-

Once the system is up and running, then the goal is to continuously improve quality by
monitoring, reviewing, and implementing appropriate changes, but on a small-scale and for a
specific area.

This roadmap can provide a basic framework to manufacturing organizations in their

transitional journey toward the implementation of Industry 4.0.

The use of lean six sigma also limits the risk of failure factors (e.g., cultural, structural,
and strategic), as manufactures have been employing these strategies for decades and will
be less resistant to their use albeit for a different type of implementation.

With the growing support from government bodies encouraging the uptake of Industry 4.0,
manufacturing organizations need to take advantage and transition into truly digital
manufacturing enterprises that can benefit the economy and build a sustainable ecosystem
for manufacturing.