Industry 4.0. Advanced and integrated SAFETY tools for tecnhical plants

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1 Industry 4.0 Advanced and integrated SAFETY tools for tecnhical plants

2 Industry 4.0 Industry 4.0 is the digital transformation of manufacturing; leverages technologies, such as Big Data and Internet of Things; requires the convergence of IT (Information Technology) and OT (Operational Technology); realizes connected factories, smart manufacturing, self-optimizing systems and digital supply chain in the cyber-physical environment.

3 The fourth Industrial Revolution Pervasive use of: data and information; computational technologies and data analysis; new materials; machines, components and automated systems digitized and connected.

4 The fourth Industrial Revolution Takes the automation of manufacturing processes to a new level by introducing customized and flexible mass production technologies. Allowes machines to operate independently, or cooperate with humans in creating a customeroriented production field that constantly works on maintaining itself. Introduces self-optimization, self-cognition, and self-customization into the industry.

5 KET in Industry 4.0 (key enabling technology) BIG data Internet of things (IoT) Augmented reality Simulation Advanced robotics High connectivity Additive manufacturing

6 BIG data Large and complex set of data that requires the definition of new tools and methodologies to extrapolate, manage and process information within a reasonable time. Big Data parameters: Volume Speed Variety

7 Internet of things (IoT) IoT is a neologism referred to the extension of the Internet to the world of objects and concrete places. Through the chips and sensors inserted inside them, the objects are able to interact with each other and with the surrounding reality. The physical world can be entirely (almost) digitized, monitored and in many cases virtualized.

8 Augmented reality Technology, associated with computer graphics, which thanks to electronic devices is able to increase the sensory perception of man. It differs from virtual reality due to the fact that experience takes place in a combination of physical environment and virtuality and not only in immateriality. The AR allows access and use of additional information, directly in their contexts of use, overlapping levels of digital information to the physical space and allowing to interact with them.

9 Additive manufacturing The set of production processes that starts from digital models, in contrast with traditional subtractive techniques (machining by removing, cutting and drilling chips). It starts from a 3D CAD model that is divided into layers by a software integrated into the machine control system, or by online services; the pattern of resulting layers guides the printer into deposition, or sintering, of the material.

10 4IR Technologies application The new technologies are already widely available and present in companies, but at present their application is still limited and sporadic, being mainly concentrated on the control of industrial process for the mass production of components (CNC machines), integrated with robotics only in certain environments, with applications limited to the repetition of the same action or task and to the remote control of the operational efficiency of the machinery.

11 4IR Technologies networks With the transformation in key 4.0 it is instead possible to manage real networks that incorporate, integrate and put into communication machinery, plants and production facilities, logistics and warehousing systems, distribution channels.

12 4IR Digital trasformation Through digital transformation - and with the use of cyber-physical production systems - the production sites are able to react more quickly, almost in real time, to changes in demand, product specifications, supply flows of raw materials optimizing transformation processes, reducing errors and defects, improving time to market and ensuring flexibility, speed and precision.

13 4IR - Integration The field of Industry 4.0 goes beyond the single enterprise as it goes beyond the single machine. Innovation 4.0 is not about introducing state-ofthe-art machinery from a technological point of view, but in knowing how to combine different technologies and in this way integrate the factory system and the production chains so as to make it an integrated, connected system in which machines, people and information systems work together to create smarter products, smarter services and smarter work environments.

14 4IR - Customization The role of the consumer-user changes: the analysis of individual needs acquires increasing importance, as well as the ability to satisfy the demand through the mass customization of the products. It becomes possible to vary the production mode in line with the variations in demand or type of product, in a logic of modularity and continuous re-configurability.

15 4IR - Benefits There are significant impacts in terms of sustainability, in particular with regard to aspects related to workplace safety, to the optimization of consumption of energy and non-energy resources, to production models of a circular nature to reduce waste, scrap and waste (production with zero defect) and to favor the recycling/reuse of materials and secondary raw materials.

16 4IR - Digitalization Digitization is a phenomenon that gives a further boost to the transformation processes, accelerating their evolutionary changes along some distinctive lines: - interconnection - virtualization Cyber-physical model - decentralization - remote interaction - real time processing and reactions.

17 4IR - Interconnection Ability of the asset to exchange information with internal systems (management system, planning systems, product design and development systems) and/or external (customers, suppliers, partners in designing and collaborative development, other sites of production, supply chain) by means of a link based on documented specifications, publicly available and internationally recognized.

18 4IR - Virtualization A "virtual copy" (digital twin) of the real system and/or its components is created and updated through data coming from appropriate sensors and for which it is possible to predict the evolution of behavior through simulations.

19 4IR Cyber-physical model The combination of physical components (systems, machines) and digital twin gives rise to the so-called cyber-physical model, which sketches production models in which the time and costs of the transition from the prototyping to the production phase are reduced, and where the production process is able to be simulated in every function and moment.

20 4IR - Decentralization The various cyber-physical components, that make up the production plant, have appropriate strategies to correct process drifts independently, and to review their behavior in the presence of anomalies.

21 4IR - Remote interaction The devices are remotely accessible so as to be able to detect data on the operation or introduce corrective measures. Typical examples of enabled functions are those of remote monitoring and maintenance.

22 4IR - Real time processing Functions that allow to collect in real time (with sampling fast enough to follow the dynamic characteristics of the related processes) the process data and to undertake the relative actions / elaborations.

23 4IR - Adavantages The adoption of digital technologies, typical of the fourth industrial revolution, allows value chains to obtain a series of advantages, that guarantee an increase in productivity and competitiveness of companies. Some of the most evident advantages, of the fourth industrial revolution, can be summarized in an improvement of:

24 4IR - Adavantages Flexibility through the production of small lots to the costs of the large scale with important consequences in terms of customization; Speed from prototyping to mass production through innovative technologies that reduce set-up times and accelerate go-to-market times; Productivity through greater operational flexibility and system reconfiguration, resulting in reduced costs and waste, increased reliability of production systems and yield quality (reduction of errors, defects and downtime);

25 4IR - Adavantages Integration of supply chains and subcontracting through improvements in procurement and logistics systems, more efficient inventory and order management, optimization of relationships with suppliers, even in a key of less conflict in open and collaborative ecosystems;

26 4IR - Adavantages Sustainability through a reduction in energy consumption and use of raw materials, emissions, with a consequent reduction of the environmental impact over the entire life cycle of the product; Product innovation thanks to new digital technologies that make it possible to revisit many products in a smart key and review service models and market approaches.

27 4IR - Adavantages Safety through a better interaction and agility of man-machine interface, that makes possible a significant reduction of errors and injuries, and an improvement in the safety and ergonomics of the workplace. Production systems, that support and assist the operators in carrying out their duties, lead to a reduction in workrelated stress and to the overcoming of some limits in terms of the availability of personnel already trained, the aging of the workforce, the integration of workers with disability.

28 SAFETY & HEALTH Safety a state in which or a place where, you are safe and not in danger or at risk. Health state of complete physical, mental and social well-being, not only consisting in the absence of sickness or illness (WHO).

29 INAIL & Industry 4.0 Inail rewards companies, with a "discount" called "oscillation for prevention" (OT/24), if they perform actions beyond the minimum required by Legislative Decree n 81/08 for the improvement of the conditions of safety and health in the workplace. Safety and security of workers, as well as being a legal and social obligation, is an advantage from an economic point of view: it allows to prevent illnesses and accidents at work and is also an important component of a company's success.

30 INAIL & Industry 4.0 Devices that can improve conditions of safety and health in the workplace: devices for human-machine interaction and for the improvement of ergonomics and workplace safety in the «4.0» logic. desks and workstations equipped with ergonomic solutions able to adapt them in an automated way to the physical characteristics of the operators (for example, biometric features, age, presence of disability).

31 INAIL & Industry 4.0 Devices that can improve conditions of safety and health in the workplace: systems for lifting/translating heavy parts or objects exposed to high temperatures able to facilitate the task of the operator in an intelligent/robotic/interactive manner; intelligent human-machine interfaces (HMI) that support the operator in terms of safety and efficiency of machining, maintenance and logistics operations.

32 INAIL & Industry 4.0 Devices that can improve conditions of safety and health in the workplace: wearable devices, communication equipment between operators and the production system, augmented reality devices and virtual reality. An example is made up of smart devices able to provide instructions on the job and to view in real time the data on the operation of the machines and on the activities that the operators will have to perform.

33 Industry 4.0 plan - MISE Two priority objectives identified by the Industry 4.0 Plan of the Ministry for Economic Development (MISE): 1) the modernization of the "instrumental goods park"; 2) the technological and digital transformation of Italian manufacturing companies;

34 Industry 4.0 plan - MISE Assets that benefit of hyper-depreciation: 1)Instrumental goods whose operation is controlled by computerized systems or managed by appropriate sensors and drives; 2)Systems for quality assurance and sustainability; 3) Devices for human-machine interaction and for improving the ergonomics and safety of the workplace in logic «4.0».

35 Industry 4.0 plan - MISE To benefit from the tax deduction of hyper-depreciation, the assets must have the following characteristics: 1. Control by means of CNC and / or PLC; 2. interconnection with the factory information systems with remote loading of instructions; 3. automated integration with the logistics system of the factory, with the supply network, with other machines in the production cycle; 4. simple and intuitive interface between man and machine; 5. compliance with the most recent parameters of safety, health and hygiene at work.

36 Industry 4.0 plan - MISE Moreover the assets must be equipped with at least two of the following additional features to make them assimilable or integrable to cyber-physics systems: a) remote maintenance and/or telediagnosis and/or remote control systems; b) continuous monitoring of working conditions and process parameters by means of appropriate sensor sets and adaptability to process drifts; c) integration between the physical machine and/or the plant with the modeling and/or the simulation of one's behavior in the development of the process (cyberphysics system).

37 Industry 4.0 plan - HMI Devices for human machine interaction aimed at improving ergonomics and devices for human machine interaction aimed at improving workplace safety: - Integrated ergonomic workstations in which the operator has at his disposal intelligent transport modules, touch screen terminals, anti-glare and customizable lighting of the workstation, elements with articulated arm, electrically adjustable work table in height; - Intelligent devices able to provide instructions on the job and to visualize in real time the data on the functioning of the machines and on the activities that the operators will have to perform.

38 SAFETY Tools - 3.0

39 SAFETY Tools Helmet; protective headphones; glasses; protective mask; work overalls; working gloves; work shoes.

40 SAFETY Tools a) How could you image 4.0 safety tools? make a list of safety tools; define, for each one, sensors that can be integrated.

41 SAFETY Tools b) Which data could be detected by advanced and integrated SAFETY Tools? Classify the type of parameters referring to: surrounding environment; physiological conditions of workers; machine parameters.

42 SAFETY Tools c) Could you define the flow of data? sensors detect parameters and send data to... data are processed by... processed data are returned to... data are recorded by... which data are recorded in the short and long term?

43 SAFETY Tools d) How 4.0 safety tools could increase the sensory perception of man? Give some examples... What advantages derive from it?

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