While initially Industry 4.0 was predominantly associated with manufacturing automation, recently there has been a subtle shift that sees the ideology applied end-to-end, encompassing the entire supply and manufacturing chain, as well as long term operation and even ongoing maintenance.

The basic concept of Industry 4.0 is widely acknowledged as stemming from the ‘Industrie 4.0’ project, covering the digitalisation transformation of manufacturing, launched by the German government, industry leaders and academics at the Hannover Messe in 2011. Since then, many more voices have joined the call for, and commentary on, Industry 4.0 and, as can be the nature of such things, each voice has a slightly different viewpoint.

Early stages

At the heart of Industry 4.0 is connectivity and the Industrial Internet of Things (IIoT); indeed some view the two concepts as, if not identical, then certainly somewhat interchangeable. And as time goes on, the benefits that implementing a connected, digitised model can bring mean that more and more manufacturers are looking at the IIoT as a way to improve their bottom lines. In fact, a recent IndustryWeek survey sponsored by Emerson revealed that about 60 percent of those surveyed are exploring or investing in Industrial IoT pilot projects. However, less positive is that just 5 percent are investing against a clear business case for how to best implement the technology. The vast majority of Industrial IoT investment today is in the early stages of plan development and small-scale trials, often as part of a larger operational efficiency programme.

The survey found the biggest challenges for operational efficiency programmes are company culture (47 percent); lack of clear business strategy (41 percent); and knowing which technology will deliver measurable improvement (34 percent).

“Early Industrial IoT successes demonstrate that manufacturers can achieve operational improvements that significantly impact the bottom line, but this survey shows that adapting to advancing technology is a significant challenge,” said Mike Train, executive president of Emerson Automation Solutions. “The small percentage of companies that have already developed clear business plans for Industrial IoT are positioning themselves to realise tremendous competitive advantages. We encourage everyone else to consider two critical first steps: start small and invest in applications that enable a clear business case.”

Even with the challenges associated with Industrial IoT and operational excellence programmes, more than half (55 percent) of respondents indicated they see an opportunity for improved operations to enhance their business’ profitability by 10 percent or more. They cited automation (31 percent) and training and competency development (31 percent) as the biggest sources for return on investment.

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According to Emerson, industrial IoT is well-suited for small-scale trial applications, such as monitoring equipment health or energy consumption within a facility. These smaller initial projects most often address clear business needs in a measurable way, while also giving manufacturers the opportunity to evaluate broader applications as they gain expertise. This approach was well-understood in the survey, with 61 percent saying the best business case is built by starting small, then scaling up.

Skills & processes

At adi Automation, managing director Ian Millington asserts that businesses should be asking how they can upgrade what they already have, in both staff skills and in manufacturing processes, in order to make the most of the increasingly connected world.

Connectivity is the key to any data-driven manufacturing implementation. This means companies must find a way to get every machine talking to the corporate network, and to do so securely, using standardised-communication protocols. To do this, it is vital to have an understanding of your current system architecture. For example, which pieces of equipment need to talk to each other? Are there legacy products which need to be incorporated or modernised for the system to work?

It is advisable to set goals as this will facilitate the most useful system set-up and collection of relevant data. Common targets include reducing the cost of production, streamlining energy usage and minimising downtime.

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That said, a connected cyber-system must be thought out carefully before implementation –  if businesses want to ensure that they benefit from Industry 4.0 they must be prepared to overcome some significant challenges. Though cybersecurity is important, with more than 200,000 malware programs launching per day, companies should not be afraid of it as there are a multitude of avenues to help mitigate the risk. This includes separation of IT (information technology) and OT (operational technology) systems, as well as setting up robust security protocols and access permissions to certain persons, who can only access data that is necessary for their job role.

adi Automation is, says Millington, witnessing a growing need for data amongst customers in all sectors. This is because they are taking on increasingly complex projects and challenges which all require accurate, valid data and visualisation tools to achieve.

Data gathering

Gathering the data that underpins Industry 4.0, David Hannaby, national product manager for presence detection at Sick UK refers to sensors as the ‘all seeing eyes’ of Industry 4.0. Trusted foot soldiers, they give machines the information they need to operate. Simple sensing tasks like detection, positioning, counting, measurement, timing and barcode reading are just as mission-critical to Industry 4.0 automation as 2D and 3D vision inspection and machinery safety, asserts Hannaby.

Thousands of different sensors support manufacturing and logistics processes.  Every second they provide a wealth of data to power operations.  However, the ability to exploit all that data to the full has been limited by the fact that it has been – in a sense – ‘trapped’ at a local processing level.  Industry 4.0 is all about releasing and sharing that data, developing new and better ways for industry to make use of it.

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If sensors already had ‘eyes’, it is the IO-Link communications gateway has given them a ‘voice’ and the ability to ‘hear’.  Now equipped with more on-board intelligent processing capability, in Industry 4.0 sensors perform more complex tasks at a machine level.  

Hannaby has identified five key considerations for any manufacturer looking to be Industry 4.0-ready:

1 Reliability and Availability

Tight margins make production downtime the enemy of FMCG manufacturing. Difficult-to-see objects uneven shapes, transparent, semi-transparent, or highly-reflective objects like glass, plastics, films and foils can often present reliability challenges.  So, in Industry 4.0 smart sensors must begin by ensuring every product is reliably detected every time.

2 Flexibility in Batch Manufacturing

Altering machinery settings and sensor parameters manually every time there is a product changeover creates downtime in batch production.  In Industry 4.0, intelligent sensors such as code readers and vision systems can detect product changes on a production line and trigger a change to new parameter settings automatically with little or no interruption.

3 Product Tracking and Traceability

In industries such as automotive, pharmaceuticals or food manufacture, for example, strict rules govern traceability across all stages of production, processing and packaging and there’s mounting pressure to make recalls in ever-decreasing timeframes.  With data collected by RFID tags, vision systems and barcode readers, Industry 4.0-enabled organisations can respond rapidly and retrieve vital data in real time.

4 Reduced Inventory and Easy Replacement

There are always times when sensors need to be replaced, and manufacturers are responding by making it as quick and easy as possible to install, commission or substitute a device.  Sensor settings and parameters are easily downloaded from a PLC to a new sensor for rapid replacement and commissioning.  At the same time, smart sensing technologies can reduce the number and type of sensors needed to be kept in stores, lowering inventory costs.

5 Diagnostics & Condition Monitoring

With the control system fully connected to “see” the sensor as a distinct and locatable device, manufacturers have access to a full range of diagnostic capabilities.  Through the combination of sensor self-monitoring and the ability to notify the control system of precisely which sensor needs to be replaced, production teams have much greater flexibility in monitoring their processes.  Pre-failure notifications can prevent failures before they happen and sensor diagnostics can be integrated into flexible, needs-based maintenance plans.

Industry 4.0 is not science fiction, asserts Hanneby. There are opportunities right now to take advantage of improving technologies and achieve production efficiencies. In terms of sensor selection, that means opting for devices that leave open a gateway to system connectivity, and at the same time, provide the most reliable and intelligent response to the specific production task required.

Digital infrastructure

Over at Schaeffler, the company is aiming to ease the transition to Industry 4.0 with a standardised and flexible digital infrastructure. With components equipped with sensors, application-specific solutions, and cloud-based services, manufacturers and operators of machines and equipment can use and apply the Internet of Things (IoT) in practice.

Schaeffler’s Smart Ecosystem 4.0 offers a comprehensive, cloud-based hardware and software infrastructure that includes every stage of digital added value – from components equipped with sensors through to digital services. The flexible architecture of this system gives manufacturers and operators of machines and equipment a simple, application-oriented point of entry into Schaeffler’s range of digital services that can be expanded at any time. The rolling bearing, its mechatronics derivatives, and the corresponding domain expertise provide the central source of information in this field.

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Components equipped with sensors are central to the drive systems used in machines and equipment – they record data and are the fundamental “enablers” for these digital services. Schaeffler’s aim is to continuously transform conventional mechanical products and integrate them into the digital world. Bearings and guidance systems equipped with sensors have already been on the market for several years. At the 2017 Hanover Messe, Schaeffler presented a rolling bearing system that is based on standard products and can be configured in a modular fashion with various different sensors, which allows virtually every desired bearing position to be equipped with sensors. This represents an important step towards a future in which not only complex systems but also simple assemblies and machines will have easy access to digitalisation and the IoT.

Schaeffler’s Cloud-capable FAG SmartCheck, which for the first time allows a simple and flexible point of entry into the digitalisation of machines and equipment based on vibration monitoring, was also on display at the 2017 Hanover Messe. This latest version of the FAG SmartCheck uses an MQTT interface to provide a direct link to the Schaeffler Cloud or to any other platform based on IBM technology. It’s also possible to communicate with other cloud technologies via a Schaeffler gateway or alternative gateway solutions using an OPC/UA interface. The connection between the SmartCheck and the Schaeffler Cloud is remarkably easy to make via smartphone, e.g. by scanning the relevant product’s QR code or using the free app.

This gives the customer direct access to services such as Schaeffler’s automated rolling bearing diagnosis, which is based on the vibration data that the FAG SmartCheck has gathered from rolling bearings as well as shafts and other rotating components. Depending on the contract, the customer gains access to the condition data, partially-automated recommended actions or, in the case of more complex machines, a connection to the Schaeffler Service Centre, which provides specific and individual recommended actions.

Diagnostics made easy

Another company leveraging digitalisation and connectivity, as well as big data, to achieve developments in diagnostics is Murrelektronik. The company’s Cube system  is a high-performance, decentralised fieldbus system that is used in many machines and systems. It has a modular structure and customised installation concepts can be realised with a large variety of input modules, output modules, mixed modules, and a wide range of function modules (e.g. IO-Link, RS 485, etc.). A one cable system transfers both communication data and supply voltages, whereby up to 32 modules can be connected to the four branches of each bus node.

When starting the Cube system, a Diagnostics Gateway reads the complete topology and also the entire process communication and all diagnostic messages. The module visually prepares this data and displays all information, independently of the control and without additional software, in each browser and, regardless of the platform, in the same way. Any user with access authorisation to the communication network may access this data, for example via the HMI, a tablet or the locally installed computer in the control station.

OEMs & systems integrators

For end users, IIoT provides cost effective, high performance integration of drives & controls in systems of any size or complexity. IIoT allows users to monitor productivity, machine state and process trends locally or remotely from any location via the Internet on an iPad, iPhone or touch screen PC. Sprint Electric is looking the advances to to be gained by OEMs and systems integrators in applying IIoT?

Even the very largest OEMs and systems integrators operate on slim margins, so any solution that can reduce build or installation cost is a significant advantage.  Consider, for example, the Sprint Electric PL/X DC Drive. Once a standalone component used to provide only motor control, the PL/X can now be fitted with a miniature smart controller transforming it into, says the company, an IIoT technological powerhouse. The IIoT enabled controller can be used to provide robust Programmable Peer Control (PPC) to control or interface with any Ethernet-configured device.

Process optimisation

Beacon and sounder manufacturer Werma views Industry 4.0 as more evolution than revolution. In fact, for the last six years the company has been developing ever more sophisticated systems – solutions for process optimisation. The core competence of Werma lies in the design and manufacture of industrial signal products which, amongst other things, display visually the status of productive machines and equipment.

Status change “data” captured by andon lights or sensors is essentially the date and time stamp of a transaction or activity which is then transferred wirelessly to software hosted on the server which then produces detailed meaningful data on the performance of the machine thus obviate the need for manual collection and collation of data.

In an Industry 4.0 context the appeal of this is clear – automatic collection of data giving transparency to an operation which can be viewed by staff anywhere around the operation.

Werma has developed three innovative intelligent systems each addressing a specific manufacturing process issue.

StockSAVER is a new Kanban replenishment system which uses sensors to detect movement of bins in and out of racks and then automatically calls up replenishment orders – no need for kanban cards or milk-round collection systems.

SmartMONITOR is a machine monitoring system using andon lights to register changes in machine status which is recorded and transferred wirelessly to software which produces report and analyses on for example fault conditions and downtime.

AndonSPEED is a call for action system for manual workstations which allows the operator to call for assistance without leaving the post.  The wireless based system puts the call for help through to the appropriate service this data is recorded automatically to help identify improvement measures.

Machine control to user

At the EMO Metal Working Trade Fair in Hanover Mitsubishi Electric and the Fraunhofer Institute for Production Technology IPT revealed a smart information system which will deliver information tailored to match the requirements of the job in hand, straight from the machine control unit to the machine operator. This will slash the time required by the operator to make a decision and will permit even unfamiliar tasks to be solved more swiftly and more flexibly.

Costs rapidly start to mount up in production when a machine unexpectedly comes to a standstill. The onus is then on the machine operator to make the right decision on the spot to get the machine running again. As a rule, the cause of a breakdown can reliably be identified and the optimum solution devised only when all relevant information has been collated to provide the bigger picture. The Fraunhofer IPT and Mitsubishi Electric have collaborated to develop a new system which can gather together all the information of relevance to the machine operator on mobile terminals and present it in processed form: Smart glasses or tablets can thus support the employee directly on the shop floor – in activities ranging from training, through monitoring and eliminating machine malfunctions through to maintenance. The new system works with commercially available smart glasses and tablets running an android operating system and can now integrate these in industrial manufacturing environments.

The smart devices and the Mitsubishi Electric machine control unit communicate directly with one another in the new system, so staff can see in real time when tasks are completed, disturbances occur, when a machine door is not properly shut or when scheduled maintenance work is coming up. The system informs the machine operator directly via pop-up on the terminal and offers help.

Information on subjects such as how to replace a tool is provided step by step in various formats such as video or text. This allows users to solve the problem promptly themselves, without having to stop one activity in order to locate and look up manuals, operating or test instructions. Companies which implement the system, can reduce machine down-time, schedule production orders more accurately and manufacture products more quickly.

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The system supports the machine operator not only in the event of disturbances and repairs, but can also monitor individual machine tool components in real time: The smart devices flash up-dated motor current levels for various drives and 3D part models are augmented into the real machine environment within the operator´s immediate field of vision. This permits the state of the components to be monitored continuously and at any given point in time. Operators can take action before an impending error occurs or may be informed by the system that a component is sustaining less wear than previously assumed, allowing them to make an informed and independent decision to extend the scheduled period between maintenance operations.

Education

With the need for new skill sets emerging, there is no doubt that embracing Industry 4.0 and all the potential benefits requires ongoing training and education. Addressing this need, Festo Didactic and SAP have created an Open Integrated Factory to give an example of how the shop floor and a Manufacturing Execution System can be linked successfully in the era of Industry 4.0. Using smart technology, work pieces in Festo Didactic’s CP Factory 'tell' the machine how they should be processed.

Based at SAP’s Experience Business Center in Paris, the facility demonstrates the integration of manufacturing and IT that is at the heart of Industry 4.0. What makes this smart assembly line of just 8.60m length special are its work pieces: They communicate to the machine how they should be processed. Not only is it capable of producing two completely different products (a remote control or components for smart meters): One of the two can actually be built in up to 16 variations.
SAP product development and the SAP Co-Innovation Lab developed this scenario as part of a co-innovation project with Festo Didactic providing the systems technology. The scenario demonstrates that this production line can be run using SAP software.

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The work pieces contain information in the form of production parameters. “The parts know what they are and can communicate with the facility through RFID technology. After approaching the correct station, they tell it which part and variant they are, and request to be processed with the appropriate method,” says Frédéric Puche, head of SAP’s Experience Business Center. Through the use of defined standards, product variations can be manufactured in any given order and quantity, all on the same production line. According to Festo, this make makes lot size 1 – the production of a single product with exact customer-defined specifications – a realistic proposal.

Maintec

As can be seen in some of the case studies covered in this focus, Industry 4.0 will usher in a new approach to maintenance activities, offering as it does, the ability to measure parameters at the coalface, and pass that data, remotely if needs be, for analysis, and dgital technologies will underpin the concept of continuous maintenance. The more data is obtained over time, the more confidence there can be in the predictions made, and this helps with planning maintenance schedules and the logistics of having spare parts available at the right time.

But, as observed by consulting editori at Western Business Publishing, like all good things, it comes at a cost: the application of digital technologies across factory settings can be a complicated and expensive activity. But its value to a business in terms of manufacturing efficiency and maintenance improvement can make it a hugely worthwhile investment.

Another dimension of the cost is the huge amounts of data – so-called 'Big Data' – which need to be stored and managed. What software systems are available to help with the analysis? Is it safe to store such data in the cloud? What are the security implications of opening up industrial networks in this way to engineers who may be using laptops, tablets and smartphones as part of their armoury?

These changing roles for the maintenance function have wider implications too. The skillset required for the maintenance engineer has changed, with new skills required, and some older ones – arguably – less important. As in all engineering disciplines, and in the light of proposed changes in the political landscape, the UK faces acute skills shortages.

 All of these issues and more will be addressed at the Maintec exhibition, which takes place at the NEC, Birmingham, 6th-7th November 2018.