In 1992 when Industrial Plant & Equipment was launched, the country was deep in recession, interest rates were high and unemployment rising, Fast forward 25 years to 2017, interest rates are low, unemployment is falling and we’re supposedly in the early stages of a new industrial revolution. On the face of it, everything looks rosy. However, we’ve just started the difficult process of untangling ourselves from the EU and, in addition to not knowing the full ramifications of that, it seems not everyone is ready for the fourth industrial revolution.

So what is Industry 4.0 and is it really the next big thing? David Robinson, market development manager at Capula, shares his view: "Industry 4.0 is about combining the physical world of products and manufacturing machines with the digital world of rapid communication, advanced data analytics and artificial intelligence. That has the potential to do all sorts of good things for manufacturers, like improving the accuracy of their demand forecasts, the flexibility of their production systems and the reliability of their assets.

"The building blocks for your industry 4.0 solutions are as likely to come from a new start-up or an adjacent industry as they are from the equipment suppliers you used in the past. The systems that can identify hidden trends in mountains of production data are often based on the approaches retailers use to learn from loyalty card data or online purchasing habits, for example. SMEs with the know-how are well placed to deliver these advancements to industry and implement upgrades to Industry 4.0 connectivity without the need for complete re-engineering.

"While technology is an essential enabler, it isn’t the whole solution. There are important cultural implications: your people will have to be comfortable switching from manual to automated processes, and ready to trust the decisions made by their data systems. And you’ll need to be bold: taking risks and experimenting with new ideas to gain vital knowhow and valuable experience." 

Moving data from big to smart
In terms of predictive maintenance, Phil Burge, country communications manager at SKF, stresses the importance of collecting data and using it correctly: “Collecting information is one thing, but making sense of it is what adds value. In modern industrial parlance, it’s about turning ‘Big Data’ into ‘Smart Data’ – which is achieved by enriching the raw data using knowledge and expertise. Gathering lots of process data and interpreting it properly gives maintenance engineers the information they need to improve running conditions. 

“Typically, customers are given detailed reports on the behaviour of machines. Although specialists such as SKF deliver many semi-automated ‘unstructured data’ reports every year, AI systems will soon be able to interpret and automatically analyse huge volumes of data. AI systems might compare a current picture with a historical one, for example, or extract data directly from a written report.

“There are hurdles to overcome before we get to this point. While the hardware and software are in place, we still need the systems from different vendors to communicate seamlessly. Interoperability has long been a concern, but the signs are that things are becoming more open – often because a single customer is served by multiple suppliers, which are under pressure to ensure that systems work harmoniously.”

Right first time

Colin Chapman, markting manager at Henkel also believes Industry 4.0 is set to take preventative maintenance to a new level: “Rather than it simply being a pre-emptive measure to minimise failure, the whole process is becoming much smarter. Sensors are now tracking and displaying machine performance in real time so that maintenance is undertaken when it is actually needed rather than when the schedule dictates.

“More than ever before, products used in the maintenance process must do the job right first time, every time. As real time repair becomes a reality, speed, efficiency and reliability are essential. It is therefore imperative that manufacturers continue to invest substantially in research and development to ensure their products deliver these qualities.

“Loctite pipe thread locking and sealing adhesives are a good case in point. Their formulations have been continually upgraded to provide new benefits and match customer expectation. The latest generation adhesives in this family are more tolerant of contamination, can be used on a wider choice of materials without an activator and can withstand higher temperature applications. They are designed to be toolbok products for all maintenance professionals implementing real-time maintenance."

Thermal imaging

Also looking at changes within the maintenance department, Andrew Baker, sales director North Europe – FLIR Systems, believes very few technologies have made such a big impact on maintenance engineering as thermal imaging: “Over 25 years it has evolved from being a very expensive and cumbersome method of detecting and measuring temperature anomalies to one that is affordable and easy to use. Indeed, for many, a thermal imaging camera is now a toolbox essential.

“Several developments have been instrumental in this technology’s rise to mainstream use in maintenance engineering. The introduction of the uncooled detector was a significant breakthrough which made cameras less complex and much more practical for industrial applications. Higher resolution detectors and image enhancement have also made fault diagnosis a lot easier.

“So what’s next? Well the development of the thermal imaging micro core is certainly the latest milestone. This has already led to the introduction of pocket-sized thermal cameras, smart phones with on-board thermal imaging and tools such as electric meters with imaging capability. By miniaturising the technology, the possibilities are endless and the next 25 years in the world of infrared are set to be just as exciting."

Adaptability key 

While Industry 4.0 is clearly a hot topic among IP&E readers, other pressing concerns include what's in store for the UK post-Brexit UK. A recent report from the Engineering and Machinery Alliance (EAMA) found that two-thirds of mechanical and electronic engineering companies expect trade barriers and cross frontier admin to cause problems. Companies typically estimate the added cost of exporting to the Rest of the World at an extra 3 to 10% and and believe this is the sort of increase they will have to absorb to be competitive.

Peter Williamson, managing director of R.A. Rodriguez (UK) & RARUK Automation, believes adaptabiliy will be a key requirement for business over the next few years: “As an import and export business, we will need to adapt as the trading mechanisms change.

“There is no doubt that UK manufacturers will need to increase their competitiveness on the world stage, and automation has a very important part to play in this regard. It will be instrumentatal in boosting productivity and ensuring consistent quality, and there is even greater potential for our collaborative robots because of their application flexibility and mobility. They will also help to compensate for any shortage in low cost labour that may result from new rules.

“It’s not just the automation side of our business that stands to benefit. As UK manufacturing output grows, so too will demand for our engineering componants and systems. And even if the unit cost of those components may be slightly higher in years to come with exchange rate fluctuations, higher volumes will increase our negotiating power.”

Three key issues

James Selka, CEO at the Manufacturing Technologies Association, brings this article to a close on a cautiously optimistic note: "The next 25 years is a big ask in our sector as we see how quickly technology moves. This is highlighted biennially at our trade show MACH.

"To remain a competitive manufacturing nation the UK needs to focus on three key things – technology, skills and finance. If these three things are in place they will lead to productivity improvements. That will keep us at the front of the pack. The UK is an innovative nation and excels in advanced engineering. I’m sure that with more and more manufacturers switching to industry 4.0 technology and embracing further automation in production, we will maintain our competitive edge.”