Industry 4.0-sgd-mar-2016
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The document discusses Industry 4.0 in the context of mechanical engineering, highlighting its evolution from early industrial revolutions to the current trend of smart manufacturing driven by the Internet of Things (IoT). It emphasizes the importance of real-time information availability, automation, and adaptive production processes while also addressing the implications for the workforce and educational institutions. Overall, it presents a vision of a hyper-connected, sustainable manufacturing environment that integrates advanced technologies and interdisciplinary collaboration.
Industry 4.0-sgd-mar-2016
- 1. 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 Management 12 MARCH 2016
- 2. 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
- 3. Where is Mechanical Engineering? • Its presence? • Its form? • Its content? • Relationship with other disciplines? • Mechanical engineering is the discipline that applies the principles of engineering, physics, and materials science for the design, analysis, manufacturing, and maintenance of mechanical systems. It is the branch of engineering that involves the design, production, and operation of machinery. • Source: https://en.wikipedia.org/wiki/Mechanical_engineering
- 4. 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
- 5. Let us get back into History !! Evolution .. First Industrial revolution Introducing 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 revolution Based 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-
- 6. Let us get into present: Smart regime.. Smart Phones Smart Homes Smart Vehicles Smart factory Smart City Technology Push Market Pull
- 7. 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
- 8. 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”?
- 9. 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
- 10. 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 Manufacturing ecosystem
- 11. 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 !
- 12. 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
- 13. Disruptive technologies behind Industry 4.0 • Analytics and Big Data • Mobile technology • AI & Robotics • Cloud Computing • Social networking
- 14. The traditional Factory • Monolithic • Hard wired • Centralized • Fixed locations • Low skill set for labor
- 15. 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
- 16. 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
- 17. 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
- 18. 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
- 19. Implications ..1.. Various connotations • Smart materials • Smart Controls • Smart manufacturing processes • Environment friendly operations • Closer to customer and pulled by smart customer trigger
- 20. 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
- 21. 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 !
- 22. 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
- 23. 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 equipment Manufactirng 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
- 24. 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
- 25. 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.
- 26. 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
- 27. My post on Linkedin about industry 4.0 • https://www.linkedin.com/pulse/industry-40-implications-technical- institutes-sanjeev-deshmukh?trk=pulse_spock-articles
- 28. 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
- 29. 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
- 30. 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
- 31. 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
- 32. 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