Industry 4.0, Smart Factory, IIoT, Connected Factory - What is it all about?

Industry 4.0 (IIoT) - What is it all about?

Industry 4.0 - Revolution and Evolution

Industry 4.0 is all about 4th Industrial revolution which has widespread applications across a variety of Industries including manufacturing and processing industry. It is about using technologically advanced systems and solutions (IIoT, Big Data, Artificial Intelligence and Machine Learning) for smart manufacturing in a connected factory or a smart factory.

IIoT means Industrial Internet of Things. It provides an ecosystem to integrate various business functions including production, planning, maintenance, finance etc. for smarter and timely decision making.

For a factory IIoT is a means to achieve Smart manufacturing in a smart connected factory (as per Industry 4.0) wherein each of the equipment communicates with other equipment and / or with the centralized software platform and constantly generates useful data in real-time (and stored historically as well).

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The data thus generated and represented through visualization can be used for making appropriate responses inline with the Industry best-practices, business goals and Company / Shop-floor requirements. It has definite advantages over SCADA / PLCs which is focused only on production or shop-floor requirements. Comparison between IIoT and SCADA follows.


Smart Factory in Industry 4.0 System Architecture

Typical Smart Factory Architecture


Benefits :
  • Improved Productivity : With access to real-time data a factory can boost it's productivity by knowing what it needs and when. Historical data results in better planning. The same integrated with business process can improve productivity and reduce wastage.


  • Intelligent Automation : Achieved through a closed-loop feedback system wherein IIoT is not just a passive system but an active system with actuators, controllers, robots, Co-bots (a fast emerging concept). It puts a lot of stress on machine learning, algorithms, data analytics etc. 
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  • Energy Efficiency : Monitored energy can result in comparative historical data and trends., with lesser human intervention and lesser errors. A closed-loop feedback system can also initiate action based on artificial intelligence learnt over a period of time.

  • Enhanced Predictability : Real-time data from various machines and equipment results in enhancing predictability about production (business use-case) and machine downtime (predictive maintenance) thereby saving a lot of money and time. It thus helps in enhanced OEE (Overall Equipment Effectiveness) as well.

  • Informed Decision making at all levels : Data is the new gold. All the business decisions, technical decisions are based on facts and figures - which are nothing but data. By equipping one self with the right data and inferences (artificial intelligence) from that data it is possible to make the most informed decision with little chance of human error or judgement.


IIoT has also been known to improve product quality through simulation and twinning. New business opportunities by identification of new breakthrough products, processes and unexplored markets through artificial intelligence is another key benefit. In a nutshell, your IIoT solution / project should first attempt to find solutions to existing problems of your plant and / or Company and then be smart enough to look at other avenues of business growth for your Company.

Enerco Energy Solutions LLP has in-house Industry 4.0 and IIoT expert team led by their CEO - Rathin Vyas who is himself a PMI and NASBA (U.S.A.) certified IIoT, Big Data, AI/ML expert. To know more do visit our website section on Industry 4.0.

If you wish to receive a FREE IIoT Guidebook (v2.0, October 2019) simply Contact Us or drop us a mail on iiot@econserve.in . We keep releasing updated version with v 3.0 slated for release in December 2019.

Comments

  1. Excellent Article !

    How can we get started for our chemical processing unit?

    Rgds,
    JP Yadav

    ReplyDelete
    Replies
    1. Dhanyawaad Sir, Kindly send an email to iot@econserve.in and we will get back with our FREE Industry 4.0 (IIoT) Guide to get you started.

      Best Regards,
      Rathin Vyas

      Delete
  2. Mr. Vyas you have mentioned about SCADA / PLCs which we already have, but where can we know more about Smart Manufacturing using IIoT?

    Thanks & Regards,
    B. Shankar

    ReplyDelete
    Replies
    1. Sir,

      You may download the "Industry 4.0 (IIoT) for Smart Manufacturing" Presentation directly from our website section on Whitepapers and Case-studies -

      https://econserve.in/whitepapers-case-studies.html

      Best Regards,
      Rathin Vyas

      Delete
  3. What is Industry 5.0 and how is it different from Industry 4.0? Can you elaborate please?

    Thanks.

    ReplyDelete
    Replies
    1. Sir,

      Industry 4.0 is about connectivity, IoT, Big Data, AI and ML. Proponents of Industry 4.0 had visualized large-scale adaption of computers for automation and it is quite likely that full realization of Industry 4.0 takes place in Industry 5.0.

      Industry 5.0 is more about human-machine collaboration to achieve superior results in terms of productivity, engineering and design. Contrary to the popular belief, Industry 5.0 will not result in mass-layoffs as it will be more about collaborative approach than machines taking over human jobs.

      Regards,
      Rathin Vyas

      Delete
  4. How do we know if we are Industry 4.0 compliant?

    Rgds.,
    Saurabh Jain

    ReplyDelete
    Replies
    1. Dear Sir,

      We can carry out an audit of your facility and identify requirements for you to become Industry 4.0 Compliant. To know more you may download IIoT Audit information brochure from our website - www.econserve.in

      Best Regards,
      Rathin Vyas

      Delete

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