At the heart of Industry 4.0, which is often referred to as the fourth industrial revolution, is the digitalization and networking of production processes. Thanks to the implementation of intelligent technologies, numerous benefits can be expected for companies. However, the changeover also poses a number of challenges. The core elements of Industry 4.0 are explained in more detail below.
What is Industry 4.0?
The central feature of Industry 4.0 is the networking of physical and virtual systems with the aim of a continuous exchange of data between the systems. This makes it possible for the individual systems to react intelligently to each other. Because the systems can control themselves to a certain extent on the basis of data analysis, often sluggish central production control elements become (partially) obsolete. In addition to increased flexibility, this also results in productivity increases and cost reductions.
Which technological foundations are crucial for Industry 4.0?
Various technologies form the basis for companies to transform themselves in line with Industry 4.0. Without these technologies, the desired networking of physical and virtual systems and their self-control is not possible. These include:
Industrial Internet of Things (IIoT)
In the Industrial Internet of Things (IIoT), physical systems are equipped with comprehensive sensor technology and connected to the internet. This allows data to be collected and exchanged in real time.
Artificial intelligence
Artificial intelligence refers to algorithms and models that can recognize and evaluate patterns and conditions and draw conclusions from them. Machine learning is also relevant in this context.
Big Data
Big data refers to the collection and analysis of gigantic collections of data that are constantly being delivered via the systems. Many important insights and optimization measures can be derived from this data.
Cloud Computing
Cloud computing makes it possible to store the enormous amounts of data that accumulate in the course of Industry 4.0. Traditional data centers can only provide the necessary capacity for this to a limited extent, which is why cloud solutions that are used via the internet are becoming established. In addition to storage capacity, cloud computing offers other IT resources on demand.
Robotics
Intelligent robots are a key factor in the increasing automation of industrial processes.
Additive production processes (e.g. 3D printing)
Additive manufacturing makes it possible to produce three-dimensional objects from digital models. These manufacturing processes allow the greatest possible flexibility with maximum customization options. A typical example is 3D printing.
Digital twins and cyber-physical systems
The linking of digital and physical systems is one of the most important foundations for the increasing automation and optimization of processes. For example, a digital twin can be used to simulate the optimization of production systems in advance, which reduces downtimes and increases the efficiency of changeovers.
What advantages does Industry 4.0 offer?
Industry 4.0 offers a number of advantages for companies. These include, for example:
Advantage 1: Increasing automation speeds up production processes. At the same time, regularly implemented optimizations ensure an increase in efficiency, while the error rate is consistently reduced.
Advantage 2: With the help of numerous sensors, the systems in Industry 4.0 not only monitor themselves, but also the products they manufacture. Continuous monitoring ensures that the quality of the products increases.
Advantage 3: Examples such as predictive maintenance can reduce maintenance and downtimes. At the same time, intelligent machines ensure optimal use of resources, which reduces production costs and is also environmentally friendly.
Advantage 4: Industry 4.0 makes it possible to make better use of innovative potential. Thanks to the numerous options for testing optimizations virtually before they are implemented in the physical system, investments in innovations are less cost-intensive and risky.
What are the challenges of Industry 4.0?
For companies that have only made limited investments in the networking of physical and virtual systems to date, the biggest challenge of Industry 4.0 is usually of a financial nature. Other aspects can also play a role:
- Data security and data protection
- Time required due to the high complexity of integration
- Qualification requirements for the workforce
- Dependence on technology
This makes it all the more important to create individual solutions that are geared towards the company's own requirements and possibilities. In many cases, step-by-step solutions have proven to be successful, as they involve less risk and at the same time require smaller investments in one go. The extent to which older systems can be upgraded and/or supplemented in order to save additional costs should also be taken into account.