dii 4.0 danish institute of industry 4.0 4.0 Industry 4.0 An Introduction to Industry 4.0 December 2016 1 Danish Intitute of Industry 4.0
dii 4.0 About DII 4.0 Danish Institute of Industry 4.0 (DII 4.0) is a Danish non-profit organisation founded with the purpose of promoting Industry 4.0 in Denmark and facilitating the adoption of Industry 4.0 in Danish manufacturing. DII 4.0 is the only organisation that deals exclusively with Industry 4.0 in Denmark. Our first and foremost responsibility is to serve as a professional body representing and safeguarding the interest of Danish corporations with respect to Industry 4.0 and other closely related areas. We bring industry professionals and companies across industries and academics together to promote Industry 4.0 and facilitate the adoption of Industry 4.0 in a joint effort. By bringing industry professionals and companies across industries and academics together we unite resources and simultaneously foster cross-company and cross-industry collaboration. In order to foster and allow for seamless and smooth collaboration, we recognise interests of conflict and competitive misalignment, thus Danish subsidiaries of foreign multinational corporations are not eligible to participate in our exclusive network if any of their activities conflict with a Danish member's interest. 2 Danish Intitute of Industry 4.0
Introduction T he world of manufacturing is beginning to undergo a seismic transition. Over the course of the last several decades, technology has been advancing with exponential speed and this growth does not seem to slow down in the future. However, the state of technology has now reached a high point of sophistication as well as a low point of cost. This is forming the basis for a profound and comprehensive advent of technology and digitisation in manufacturing. This transition is referred to as the fourth industrial revolution that will transform the manufacturing world. The fourth industrial revolution, also termed Industry 4.0, was originally coined by the German government and refers to the technological revolution of digitisation and ubiquitous connectivity enabled by technological advancements and cyber-physical systems. Special revolution Industry 4.0 is fundamentally different from the prior periods of industrial revolution due to the following four aspects: 1. Increased pace of change 2. Increased complexity 3. Less replacement of core production equipment 4. More disruption 1) Increased pace of change As the change of this revolution, and the ensuing digital transformation, is greatly accelerated by quickly and exponentially growing technologies, the pace of change of this fourth industrial revolution is greatly increased. This pace of significant change increases the need for development; development in terms of adapting to the new world and dynamics of digitisation and ubiquitous implementation of electronics and information-based technologies. 3 Danish Intitute of Industry 4.0
2) Increased complexity With ubiquitous connectivity, Internet of Things (IoT) devices, advanced technology such as robotics, and complex software applications, the complexity of production will increase substantially with the adaption to Industry 4.0. Just as technologies are developing at exponential speed, so does the complexity. Industry 4.0 will therefore be an industrial revolution of unprecedented complexity. Exhibit 1 Degree of complexity within the Industrial Revolution Industry 4.0 Degree of complexity Exponentially growing complexity Industry 3.0 Industry 2.0 Industry 1.0 18 th century 19 th century 1970 s Today 4 Danish Intitute of Industry 4.0
3) Less replacement of core production equipment Exhibit 2 Percentage of replacement through the industrial revolutions Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0 Water & Steam Electricity IT & Technology Cyber-physical systems Replacement of existing machinery and equipment, % of installed 100 % 10-30 % 70-80 % 40-70 % Looking at the equipment replacement perspective, the first and third industrial revolution experienced the highest levels of replacements. Very simplified, the fourth industrial revolution is about connecting existing manufacturing units and digitising existing manufacturing processes, thus a lesser extent of equipment replacement will be needed compared to the third industrial revolution where tooling equipment was replaced by machines. Future manufacturing facilities will largely look as they do today (besides the general trend in terms of increased automation and use of technology in manufacturing), but they will be different in the sense that manufacturing facilities will move from being a collection of mostly independent and isolated devices and units into a collection of fully integrated and connected devices and units being controllable from one single platform. 5 Danish Intitute of Industry 4.0
Exhibit 3 From isolation to integration Past industrial revolutions Industry 4.0 4) More disruption Both the breadth and depth of the changes that Industry 4.0 will precipitate will be of immensely more profound character than previously seen in the other industrial revolutions. While the previous industrial revolutions mostly improved efficiency, Industry 4.0 does not only offer improvements in terms of efficiency, but Industry 4.0 also offers an enormous amount of opportunities in terms of new value creating activities as well as areas of differentiation, as Industry 4.0 allows for the individual manufacturer to achieve higher levels of quality, delivery time, flexibility as well as transition towards a mass customisation approach instead of the mass production approach seen especially during the third revolution. Where it all began The term Industry 4.0 originates from the German government s 2006 High Tech Strategy. In 2010, some of the features of Industry 4.0 were described in Germany s industrial policy. However, despite these events occurred early, the first reference to Industry 4.0 did not occur until 2011. Based on a huge potential, the government in Germany began to increase their funding to further research and examination with the desire to become a pioneer and frontrunner of the fourth industrial revolution Industry 4.0. Today, the phenomenon, Industry 4.0, is widely spread across all continents. 6 Danish Intitute of Industry 4.0
Industry 4.0 what is it? The world of manufacturing is starting to experience a revolution the fourth industrial revolution. The first industrial revolution, with its days of glory in the 18 th century, utilised water and stream power in order to mechanise their production. By the 19 th century, the world of manufacturing became revolutionised by the second industrial revolution. The second industrial revolution used electric power and assembly lines to enable mass production. The rise of IT and technology led to a third industrial revolution in 1970s; automation of the production, which improved productions worldwide and made mass production more efficient. Now, the world of manufacturing is undergoing a new and fourth industrial revolution; a technological and digital revolution. The fourth industrial revolution, also termed Industry 4.0, is being characterised as an increasingly digitisation and interconnection of value chains and business models. Industry 4.0 creates Smart Factories and is based upon cyber-physical systems allowing the manufacturer to control the entire production from one platform. Exhibit 4 The Industrial Revolution transition 1.0 2.0 3.0 4.0 Period 18 th century 19 th century 1970s Today Description Enablers Characteristics Steam power Water power Mechanisation Electricity Assembly line Mass production IT Technology Automation Cyber-Physical Systems Digitisation The term Industry 4.0 is widely spread, but in the countries such as The United States and other English speaking countries Industry 4.0 is often being referred to as Internet of Things (IoT) or the Industrial Internet. However, regardless of term, they all have in common that they have embraced modern IT and gone beyond automation. 7 Danish Intitute of Industry 4.0
Exhibit 5 Industry 4.0 Manufacturing RFID All goods equipped with RFID sensors Automatic analytics Automatic quality control Everything is connected and controllable via 1 device Real-time production data Autonomous robot Autonomous vehicles in the production 8 Danish Intitute of Industry 4.0
Adoption of information and communication technology (ICT) from the world of manufacturing have enabled the companies to obtain Cyber-physical systems (CPS) a merge of the real and the virtual world. CPS are systems of cooperating and connected computational components that control physical objects. Because of their connectivity it allows them to communicate and cooperate. The smart machines constantly send useful information out regarding faults, demands, effectiveness, etc. However, smart machines are not the only elements that are smart. Among other things, smart homes, logistics and grid represent other smart elements. Together, the various smart elements form a network makes the foundation for a Smart Factory. The smart physical elements create a network beyond the entire value chain and product life cycle (PLC). Sensors and other technologically controlled elements enable the smart machines to be connected with a variety of different networks and physical elements. Industry 4.0 Enablers Exhibit 6 DII 4.0 s House of Industry 4.0 AI & Machine learning Augmented reality Horizontal & vertical integration Additive manufacturing Camera technology Cyber security Big data Specific enablers IoT x Industry 4.0 The cloud Scanning technology Simulation Software & algorithms Autonomous robots Mobile devices Computernational power Fundamental enablers Cost Internet Technological Sophistication 9 Danish Intitute of Industry 4.0
Fundamental: Cost: While the technological advancements are developing at exponential speeds, likewise are the costs decreasing exponentially. The cost of technology is important, as manufacturers are reluctant to adopting unprofitable opportunities. Now, the cost level has reached a sufficiently low point of cost. Technological sophistication: A lot of the technologies that are driving Industry 4.0 have existed for many years, however, in recent years the level of technological sophistication has increased so dramatically that they are actually implementable in a value creating way, which they were not before. Internet: The internet is the very enabler of the fourth Industrial revolution, as it allows connectivity. Furthermore, the constantly decreasing price as well as the constantly increasing quality of the internet is an important and vital driver of Industry 4.0. Specific: Autonomous robots While current robotics represent a very cost-efficient means of producing, they are limited to certain standardised work tasks with no to little variation. However, autonomous robots have the ability to perform a wider range of work tasks, and most importantly; they have the ability to work interactively and flexibly with humans or other units and systems. Simulation Due to the advent of highly advanced and sophisticated simulation software, manufacturers are now able to create highly precise, highly detailed and highly interactive virtual models of the reality. This allows manufacturers to carry out tests virtually, which is a more cost-efficient and fast alternative in terms of testing. E.g. manufacturers will be able to create virtual models of production designs, thus it is now possible to test and optimise before actually changing the production design physically. Other scenarios include a fast and cheap alternative to physical prototyping, as manufacturers are able to create virtual prototypes. 10 Danish Intitute of Industry 4.0
Horizontal and vertical integration With fully digitised and connected operations and processes, manufacturers now have the opportunity to achieve integration of their operations on an unprecedented level, both horizontally and vertically. Horizontally speaking, manufacturers are able to integrate selected operations and processes with their suppliers and partners on the upstream side as well as customers on the downstream side. This enables greater efficiency and automating on the cost side, but also fosters innovation, speed and flexibility on the value creating side. Vertically speaking, manufacturers can integrate all their internal operations and achieve fully automated and flexible processes allowing for more lean operations, efficiency improvements, increased reactiveness as well as increased speed of production. IoT The industrial Internet of things, IoT, is an important and vital driver in terms of enabling truly smart factories. IoT represents the connection of physical objects - i.a. devices, vehicles, goods under manufacturing, employees etc. The connection of such objects is achieved through embedding these with sensors and network connection etc. allowing these objects to become fully integrated in networking systems and thereby allowing them to work interactively. Cyber security With highly digitised and fully connected manufacturing processes, manufacturers are extremely exposed digitally with respect to cyber threats. Moreover, in order to be a fully smart and digitised factory, manufacturers will have to rely on a number of different suppliers. This high amount of different suppliers represents further risk. Moreover, horizontal integration represents a high degree of risk, as integration and connection with partners and suppliers exposes manufacturers even more. Thus, it is critical that manufacturers invest sufficiently in cyber security and demand a high level of security from their suppliers and their partners. The cloud The cloud offers a flexible and cost-efficient means of storing data and connecting different applications. Data and data sharing will be a particularly characteristic feature of Industry 4.0, and the cloud represents a very cost-efficient, highly reactive and highly accessible means of hosting and sharing data. 11 Danish Intitute of Industry 4.0
Additive manufacturing Additive manufacturing, or 3D printing manufacturing, represents a completely new means of production. Additive manufacturing will allow companies to produce more cost-efficiently, faster, more flexibly and more precisely. The manufactures can also benefit from this, as they are able to move towards more mass customisation, where manufactures are able to provide products that fit customers individual needs. Augmented reality Augmented reality represents an attractive opportunity in terms of assisting workers on a variety of different tasks. Augmented reality is particularly attractive when providing workers with information to assist decision-making and performing particular tasks, everything in realtime. E.g. maintenance workers may receive real-time support and guidance in terms of choosing spare parts and subsequently where and how to place them. By using glasses as a means of augmented reality, workers have both of their hands free while having constant access to information shown on the display screen of the glasses. Big data and Analytics Big data is a very important part of industry 4.0. Due to connectivity and digitisation, data is accessible for everything and recorded 24/7 with frequent data collection, thus manufacturers will have an increased amount of data available; both in breadth (number of platforms that the data is available on), but also in depth (what amount of data is available for each platform). Looking at breadth, manufacturers will have access to data on several platforms that they previously did not have. In terms of depth, companies will have very large datasets improving data quality and precision of analytics. In relation to big data, advanced analytics software is absolutely vital in order to turn data into actual actionable insights. This allows companies to identify areas of improvement on a number of areas, e.g. production quality, energy consumption, equipment utilisation, flexibility, decision-making, maintenance, waste etc. Computational power This ubiquitous connectivity creates an enormous amount of data. Therefore, a high level of computational power is vital in terms of actually enabling the handling and analysis of that data. 12 Danish Intitute of Industry 4.0
AI & Machine learning Artificial intelligence (AI) is still an underdeveloped technology, but represents an important technology for the future. Artificial intelligence is important in terms of enabling truly intelligent manufacturers, where units are able to autonomously filter and analyse data generated by other units, devices and systems, and choose its own course of action on the basis thereof. Artificial intelligence also enables machine learning. Machine learning will be particularly interesting, as it will let machines and systems improve autonomously based on daily operations. Mobile devices Mobile devices allow manufacturers and its employees to access information and control systems easily, cheaply and most importantly anywhere; not only in fixed locations. Scanning technology Scanning technologies are beginning to reach a level of sophistication that allow them to perform some tasks that are currently performed by human labour. E.g. scanning technologies can assist in terms of quality check at higher speed and precision than human labour allowing for cost savings, however, increasing capital intensity. Camera technology Modern and sophisticated camera technology has the ability to assist in terms of quality check and process auditing. Camera technology can e.g. automatically check for color discrepancies, deviations with respect to physical and geometric properties. Moreover, cameras are now able to serve as the eyes of machines and robotics. This feature is particularly important for Industry 4.0, as this will allow machines to interact flexibly and autonomously. Software & algorithms Software & algorithms will particularly important for Industry 4.0, as it will be the very driver and foundation of most systems. Analytics software will be vital in terms of analysing big data leading to efficiency improvements and capital intensity reductions. Software will also function as the liaison between systems and devices enabling automation across the entire value chain, and therefore allowing for increased productivity and cost savings. Advanced algorithms will enable robotics and equipment to act autonomously. 13 Danish Intitute of Industry 4.0
Benefits In recent years, Industry 4.0 has gained increased attention, but there has definitely been a reason; Industry 4.0 offers a wealth of valuable opportunities and benefits. Process reliability: Processes characterised by technology and digitisation are less likely to vary and cause errors, contrary to processes characterised by human labour. Moreover, by utilising connectivity and analytics, manufacturers will increasingly be able to identify process variations, and thus be able to remedy such. Production efficiency: Industry 4.0 will be a huge driver of productivity. With increased connectivity, companies have access to necessary and important data, and with advanced analytics companies will rather easily be able to turn that data into actionable insights leading to productivity improvements and increased efficiency. Moreover, the implementation of automating technology, and other Industry 4.0 related technologies, will lead to direct productivity improvements. Flexibility: By connecting every aspect of the production as well as digitising all processes, manufacturers will be able to monitor and control their production a lot more flexibly. Industry 4.0 allows fully integration vertically, thus manufacturers will be able to have all their value chain operations fully integrated. This means that changes in some parts of the value chain automatically are communicated to the other value chain operations. This, combined with advanced software and artificial intelligence, will allow the other parts of the value chain to autonomously and automatically adjust to the changes. Moreover, advanced robotics and manufacturing equipment offer flexibility with respect to the increased range of operations that they are able to perform. Increased added value: While Industry 4.0 offers numerous ways of boosting efficiency, Industry 4.0 also offers a wealth of opportunities in terms of adding value. E.g. Industry 4.0 makes it possible for manufacturers to offer individual customisation to customers, increased speed of delivery and increased peripheral services. 14 Danish Intitute of Industry 4.0
Less errors and less waste: Industry 4.0 will be an enabler of true LEAN operations. By digitising processes and increasingly replacing human labour with advanced machinery and technology, manufacturers will be able to reduce the number of production errors, as machines and technology are less prone to error compared to humans. Furthermore, by utilising big data and advanced analytics, manufacturers will be able to identify areas of waste as well as being able to improve the planning and thus reducing overproduction. Sustainability & Resource management: Industry 4.0 offers a more sustainable and responsible means of manufacturing from a resource and environmental perspective. First of all, manufacturers will be able to adopt to a more sustainable and environmentally friendly means of industrial value creation by simply reducing waste and reducing errors. Thus, it will be more uncommon that valuable resources will be wasted. Secondly, by utilising advanced analytics, manufacturers will be able to optimise processes specifically with respect to consumption of various resources such as energy, water, raw materials etc. Lower maintenance costs: Industry 4.0 offers a wide array of opportunities in terms of reducing maintenance cost significantly. Most notably; predictive maintenance. By applying advanced algorithms on the vast amount of data that machines generate, manufacturers can predict optimal points of maintenance allowing for full utilisation of the parts of the machines but also avoiding costly equipment failures and machine breakdowns. Additionally, 3D manufacturing technologies will allow companies in the future to produce their own spare parts for their machines, which will drive down maintenance cost significantly, and at the same time increase maintenance speed greatly. Improved decision-making: With an enormously increased amount of data combined with increasingly advanced analytics software, employees will be able to base their decision-making on actual data and less on gut and instinct. Moreover, based on algorithms and artificial intelligence, units and systems will even be able to carry out decision-making themselves without human intervention. Higher customer satisfaction: As a result of increased individualisation, improved quality, improved reliability, improved speed of delivery etc., Industry 4.0 will create a surge in customer satisfaction. 15 Danish Intitute of Industry 4.0
Quality improvement & consistency: By increasingly adopting technology in the manufacturing and digitising processes, manufacturers are able to increase the quality of their products. Moreover, advanced analytics can also assist in improving quality. Due to the fact that processes characterised by technology and digitisation are less likely to vary, manufacturers will also be able to improve quality consistency. Planning: With an increased amount of data as well as increasingly advanced analytics software combined with an increased level of horizontal integration, manufacturers have greatly improved conditions for improving their planning operations. Real-time: Industry 4.0 makes it possible for everything to happen in real-time. Machines and devices are capable of adjusting autonomously and automatically in real-time based on changes in other spheres of an ecosystem. Additionally, employees are able to access data and analytics in real-time. This aspect of real-time greatly increases manufacturers' responsiveness. R&D: With increased horizontal integration and big data analytics, companies will have access to valuable customer insights that can drive R&D excellence; both in terms of speed and accuracy. Moreover, new technologies such as 3D manufacturing and advanced simulation software let companies develop prototypes faster and more costefficiently, allowing for more LEAN and quicker R&D operations. New business models & revenue streams: This advent of new industrial technologies breaks ground for the birth of completely new and disruptive methods of differentiation as well as value-creation within the entire value chain - both primary and supporting activities. This new and added value-creation allows companies to tap into new revenue streams. Horizontal integration & Vertical integration: Industry 4.0 enables companies to integrate their activities horizontally - both with suppliers and partners. Especially activities related to logistics, production and R&D will benefit from this integration. More efficient and accurate logistics operations, more efficient production processes with less tied up capital, and development new and better products are just some of the benefits of this horizontal integration. 16 Danish Intitute of Industry 4.0
Exhibit 7 Horizontal and vertical value chain Horizontal value chain Suppliers Company Client Network of suppliers Planning Network of clients Business partners Procurement Manufacturing Logistics Horizontal value chain Vertical value chain Company Sales & Marketing Research & Development Planning Procurement Manufacturing Logistics Service IT Vertical value chain Finance, tax & legal Data: Due to ubiquitous connectivity, enabled by IoT, digitisation and information and communication technologies, as well as both horizontal and vertical integration, an enormous amount of data is generated. Data that prove very valuable to those who manage to translate that data into actual actionable knowledge. Customer Individualisation: As a result of autonomous electronics, data and related IT programmes, it is now possible to have flexible manufacturing technologies that are controlled automatically on the basis of data achieved from integration and connectivity. E.g. when customers' individualised orders are placed in the sales sphere, they are automatically processed and transferred to the production operations (vertical integration), and the production equipment. 17 Danish Intitute of Industry 4.0
Challenges: Decentralisation: Due to increased general technological sophistication as well as highly advanced algorithms and artificial intelligence, units and systems are now highly capable in terms of controlling themselves according to other units and other systems in the ecosystem allowing for a higher and unprecedented degree of decentralisation in terms of decisionmaking and control. While the opportunities and benefits are many and large, a number of challenges and risks are holding the adoption of Industry 4.0. Change and culture: Transitioning into industry 4.0 and its related areas represents a major change. A change that involves fundamentally different ways of working and fundamentally different people; thus, this adoption will most likely cause a change in the culture. Therefore, companies will have to manage and balance the existing values and existing culture as well as catering to the new changes. Workforce: Transitioning towards industry 4.0 entails a shift in the workforce. While a lot traditional manufacturing jobs - production, assembling, handling, processing, fabricating etc. - will be lost due to technology, workers will be needed to manage and develop the technology, thus a substantial amount of new jobs within IT, data science, engineering, technology etc. will be created. This change in the workforce greatly affects current operations related to recruiting, planning and training. Companies will have to both retrain existing employees, but at the same time hire new talent. The right workforce will be an imperative to success within industry 4.0. Complexity: With ubiquitous connectivity, IoT devices, advanced technology such as robotics, and complex software applications, the complexity of production will increase substantially. However, it is important to distinguish between the actual underlying complexity and the complexity that is perceived and experienced. There is no doubt that the actual complexity of manufacturing will increase significantly with the advent of industry 4.0 related technologies. What is important to remember is that industry 4.0 also brings a vast amount of opportunities in terms of managing that complexity. Manufacturers will use a lot of technologies and applications from external vendors, thus a great deal of the complexity will be dealt with by suppliers and technology generally, which will ultimately reduce the actual perceived complexity by manufacturers themselves. 18 Danish Intitute of Industry 4.0
Cyber risk: With highly digitised and fully connected manufacturing processes, manufacturers are extremely exposed digitally with respect to cyber threats. Moreover, in order to be a fully smart and digitised factory, manufacturers will have to rely on a number of different suppliers. This high amount of different suppliers represents further risk. Moreover, horizontal integration represents a high degree of risk, as integration and connection with partners and suppliers exposes manufacturers even more. Thus, it is critical that manufacturers invest sufficiently in cyber security and demand a high level of security from their suppliers and their partners. Data ownership: Industry 4.0 will for most companies entail an increased level of horizontal integration as well as working with third-party providers to a greater extent. Above aspects combined with ubiquitous connectivity result in huge amounts of data being shared across the entire value chain as well as shared with partners. This raises inevitable issues with respect to data ownership. Companies will therefore, have to include data ownership as part of their contracts and ensure that their partners have instituted processes, which protect their data. Standards and interoperability: A substantial amount of the current systems, applications and technologies that companies currently use are proprietary. Most of the new technologies and applications are being developed by different companies. Above aspects represent significant technical obstacles regarding interoperability; new technologies and applications need to be developed in a way that allows for interoperability with each other but also allows for interoperability with manufacturers' current technologies and applications. This poses a significant challenge as capturing the full value of industry 4.0 very much depends on interoperability. However, governments, major companies and associations are in the process of setting up industry wide standards. Standards allowing for seamless interoperability will be a major and important step in the right direction of increased adoption of Industry 4.0 related technologies. 19 Danish Intitute of Industry 4.0
From hype to value: In recent years, a lot of hype have been created around Industry 4.0. However, there is no doubt that Industry 4.0 offers a wealth of opportunities, but identifying the most optimal solutions and actually implementing them represents a major challenge due to the fact that such endeavours requires certain capabilities; capabilities which most companies at the moment do not hold. Management: For some companies, a major challenge to transitioning towards Industry 4.0 lies within in the senior management. Senior management might not be committed fully to Industry 4.0 due to lack of belief in terms of the potential of industry 4.0, or they may simply not hold the necessary capabilities. Capital intensity: It is widely argued that industry 4.0 represents an era of higher capital intensity. However, it is important to remember that some aspects of industry 4.0 point in the direction of lower capital intensity: Natural development; the cost of technologies decreases exponentially. A lot of the new technologies offers a lower capital intensive means of production; e.g. 3D printing is a lot less capital intensive than traditional manufacturing equipment. Industry 4.0 allows a fully integrated and connected value chain, which allows manufacturers to achieve; (1) a high level of flexibility and agility, allowing manufacturers as well as semimanufacturer to have less stock of raw materials, and (2) the opportunity for analysis allowing manufacturers to identify opportunities in terms of LEAN and improvements, which in the end cause less capital to be tied-up. New business models such as IMaaS (industrial machines as a service), where manufacturers do not have actually own the machines, but rather pay for the functionality (service) of the machines on a more variable basis. That being said, transitioning towards Industry 4.0 requires companies to invest in sensors and, to some extent, new production equipment, and therefore manufacturing à la Industry 4.0 represents a more capital intensive means of production for most companies, at least in the short term. 20 Danish Intitute of Industry 4.0
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