Industry 4.

CHAPTER – 1

INTRODUCTION

The term Industry 4.0 refers to the combination of several major innovations in digital technology,
all coming to maturity right now, all poised to transform the energy and manufacturing sectors.
These technologies include advanced robotics and artificial intelligence; sophisticated sensors;
cloud computing; the Internet of Things; data capture and analytics; digital fabrication (including
3D printing); software-as-a-service and other new marketing models; smartphones and other
mobile devices; platforms that use algorithms to direct motor vehicles (including navigation tools,
ride-sharing apps, delivery and ride services, and autonomous vehicles)

Manufacturing has undergone several eras of change from the first industrial revolution (use of
steam power and mechanical production), to the second (use of electricity and mass production)
and a third era defined by increased automation of manufacturing processes due to the use of
information technology (IT). A fourth era of change – Industry 4.0 – is driven by trends on
connectivity, service orientation, advanced materials and processing technology, and collaborative
advanced manufacturing networks; networks of advanced manufacturing devices controlled by
computers combining them into a physical – digital environment. This change includes the entire
value chain from raw materials to end use to recovery, impacting business and support functions
too (e.g. supply chain, sales).

Industry 4.0 creates new design principles along which the industry can organize itself, these
include: increased interoperability between manufacturing networks through increased
connectivity, virtualization of manufacturing processes by linking sensor data (from monitoring
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physical processes) with virtual plant and simulation models, decentralized decision making, real-
time capability to collect and analyze data and provide insights, flexible adaptation to changes by
reconfiguring individual modules and an increased services orientation.

Consequently, Industry 4.0 will create opportunities for new business models, solution offerings,
and new products. As manufacturers consider reasons to pursue an Industry 4.0 strategy, at some
point in the future, the transition will challenge an organization’s ability to adjust. These
challenges will come in many forms, likely linked to the incorporation of new IT capabilities, the
impact of exponentially increasing amounts of data from sensors and connected devices in the
operating environment, suppliers, and from the distribution network as we see the emergence of
self-regulating and adapting supply systems. At the same time, risks will emerge related to data
security associated with increased connectivity.

Fig. 1.1: Industry 4.0 Overview

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 Industry 4.0

CHAPTER-2

HISTORY

2.1 First Industrial Revolution

The First Industrial Revolution was marked by a transition from hand production methods to
machines through the use of steam power and water power. The implementation of new
technologies took a long time, so the period which this refers to was between 1760 and 1820, or
1840 in Europe and the United States. Its effects had consequences on textile manufacturing,
which was first to adopt such changes, as well as iron industry, agriculture, and mining although
it also had societal effects with an ever-stronger middle class. It also influenced British industry
at the time.

2.2 Second Industrial Revolution

The Second Industrial Revolution, also known as the Technological Revolution, is the period
between 1871 and 1914 that resulted from installations of extensive railroad and telegraph
networks, which allowed for faster transfer of people and ideas, as well as electricity. Increasing
electrification allowed for factories to develop the modern production line. It was a period of great
economic growth, with an increase in productivity, which also caused a surge in unemployment
since many factory workers were replaced by machines.

2.3 Third Industrial Revolution

The Third Industrial Revolution, also known as the Digital Revolution, occurred in the late 20th
century, after the end of the two world wars, resulting from a slowdown of industrialization and
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technological advancement compared to previous periods. The production of the Z1 computer,

which used binary floating-point numbers and Boolean logic, a decade later, was the beginning of
more advanced digital developments. The next significant development in communication
technologies was the supercomputer, with extensive use of computer and communication
technologies in the production process; machinery began to abrogate the need for human power.

4. Industrial
revolution
Based on cyber-
physical-world.
3. Industrial revolution systems
Through the use of electronics
and IT further progression in
autonomous production
2. Industrial revolution
Introducing 2. Industrial
revolution Introducing mass
production lines powered by
electric
1. Industrial revolution energy
Introducing mechanical
mass production
production machines powered
lines powered by electric Industry 3.0 In
Industry 1.0 Industry 2.0 Industry 4.0
by water and steam
energy Beginning of the Beginning of the
End of the Today’s World

18th century. 20th century 1970th

Fig 2.1: Phases of industries

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CHAPTER-3

Fourth Industrial Revolution

In essence, the Fourth Industrial Revolution is the trend towards automation and data exchange in
manufacturing technologies and processes which include cyber-physical systems (CPS), IoT,
industrial internet of things, cloud computing, cognitive computing, and artificial intelligence.

The Fourth Industrial Revolution marks the beginning of the Imagination Age.

3.1 Key themes

Industry 4.0 increases operational efficiency. Four themes are presented that summarize an
Industry 4.0

 Interconnection — the ability of machines, devices, sensors, and people to connect and
communicate with each other via the Internet of things, or the internet of people (IoP)
 Information transparency — the transparency afforded by Industry 4.0 technology provides
operators with comprehensive information to make decisions. Inter-connectivity allows
operators to collect immense amounts of data and information from all points in the
manufacturing process, identify key areas that can benefit from improvement to increase
functionality.
 Technical assistance — the technological facility of systems to assist humans in decision-
making and problem-solving, and the ability to help humans with difficult or unsafe tasks
 Decentralized decisions — the ability of cyber physical systems to make decisions on their
own and to perform their tasks as autonomously as possible. Only in the case of exceptions,
interference, or conflicting goals, are tasks delegated to a higher level.

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3.2 Distinctiveness

Proponents of the Fourth Industrial Revolution suggest it is a distinct revolution rather than simply
a prolongation of the Third Industrial Revolution. [8] This is due to the following characteristics:

 Velocity — exponential speed at which incumbent industries are affected and displaced [8]
 Scope and systems impact - the large amount of sectors and firms that are affected[8]
 Paradigm shift in technology policy — new policies designed for this new way of doing are
present. An example is Singapore's formal recognition of Industry 4.0 in its innovation
policies.

Critics of the concept dismiss Industry 4.0 as a marketing strategy. They suggest that although
revolutionary changes are identifiable in distinct sectors, there is no systemic change so far. In
addition, the pace of recognition of Industry 4.0 and policy transition varies across countries; the
definition of Industry 4.0 is not harmonized.

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CHAPTER-4

Components of Industry 4.0

The application of the Fourth Industrial Revolution operates through:

 Mobile devices
 Internet of things (IoT) platforms
 Location detection technologies (electronic identification)
 Advanced human-machine interfaces
 Authentication and fraud detection
 Smart sensors
 Big analytics and advanced processes
 Multilevel customer interaction and customer profiling
 Augmented reality/ wearables
 On-demand availability of computer system resources
 Data visualization and triggered "live" training .

Fig 4.1: Components of industries

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Mainly these technologies can be summarized into four major components, defining the term
“Industry 4.0” or “smart factory”

 Cyber-physical systems
 Internet of things (IoT)
 On-demand availability of computer system resources (e.g. cloud computing)
 Cognitive computing

Industry 4.0 networks a wide range of new technologies to create value. Using cyber-physical
systems that monitor physical processes, a virtual copy of the physical world can be designed.
Characteristics of cyber-physical systems include the ability to make decentralized decisions
independently, reaching a high degree of autonomy.

The value created in Industry 4.0, can be relied upon electronic identification, in which the smart
manufacturing require set technologies to be incorporated in the manufacturing process to thus be
classified as in the development path of Industry 4.0 and no longer digitisation.

4.1 Primary drivers of Industry 4.0

1. Digitization and integration of vertical and horizontal value chains

2. Industry 4.0 integrates processes vertically, across the entire organization, including
processes in product development, manufacturing, structuring, and service; horizontally,
Industry 4.0 includes internal operations from suppliers to customers as well as all key
value chain partners.

3. Digitization of product and services

4. Integrating new methods of data collection and analysis–such as through the expansion of
existing products or creation of new digitized products–helps companies to generate data
on product use in order to refine products.
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5. Digital business models and customer access

6. Customer satisfaction is a perpetual, multi-stage process that requires modification in real-

time to adapt to the changing needs of consumers .

4.2 Smart factory

Smart Factory is the vision of a production environment in which production facilities and logistics
systems are organized without human intervention.

The Smart Factory is no longer a vision. While different model factories represent the feasible,
many enterprises already clarify with examples practically, how the Smart Factory functions.

The technical foundations on which the Smart Factory - the intelligent factory - is based are cyber-
physical systems that communicate with each other using the Internet of Things and Services. An
important part of this process is the exchange of data between the product and the production line.
This enables a much more efficient connection of the Supply Chain and better organisation within
any production environment.

The Fourth Industrial Revolution fosters what has been called a "smart factory". Within modular
structured smart factories, cyber-physical systems monitor physical processes, create a virtual
copy of the physical world and make decentralized decisions. Over the internet of things, cyber-
physical systems communicate and cooperate with each other and with humans in synchronic time
both internally and across organizational services offered and used by participants of the value
chain .

4.3 Predictive maintenance

Industry 4.0 can also provide predictive maintenance, due to the use of technology and the IoT
sensors. Predictive maintenance – which can identify maintenance issues in live – allows machine
owners to perform cost-effective maintenance and determine it ahead of time before the machinery
fails or gets damaged. For example, a company in Los Angeles could understand if a piece of

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equipment in Singapore is running at an abnormal speed or temperature. They could then decide
whether it needs to be repaired.

4.4 3D printing

The Fourth Industrial Revolution is said to have extensive dependency on 3D

printing technology. Some advantages of 3D printing for industry are that 3D printing can print
many geometric structures, as well as simplify the product design process. It is also relatively
environmentally friendly. In low-volume production, it can also decrease lead times and total
production costs. Moreover, it can increase flexibility, reduce warehousing costs and help the
company towards the adoption of a mass customization business strategy. In addition, 3D printing
can be very useful for printing spare parts and installing it locally, therefore reducing supplier
dependence and reducing the supply lead time.

The determining factor is the pace of change. The correlation of the speed of technological
development and, as a result, socio-economic and infrastructural transformations with human life
allows one to state a qualitative leap in the speed of development, which marks a transition to a
new time era.

4.5 Smart sensors

Sensors and instrumentation drive the central forces of innovation, not only for Industry 4.0 but
also for other “smart” megatrends, such as smart production, smart mobility, smart homes, smart
cities, and smart factories.

Smart sensors are devices, which generate the data and allow further functionality from self-
monitoring and self-configuration to condition monitoring of complex processes. With the
capability of wireless communication, they reduce installation effort to a great extent and help
realize a dense array of sensors.

The importance of sensors, measurement science, and smart evaluation for Industry 4.0 has been
recognized and acknowledged by various experts and has already led to the statement "Industry
4.0: nothing goes without sensor systems."
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However, there are a few issues, such as time synchronization error, data loss, and dealing with
large amounts of harvested data, which all limit the implementation of full-fledged systems.
Moreover, additional limits on these functionalities represents the battery power. One example of
the integration of smart sensors in the electronic devices, is the case of smart watches, where
sensors receive the data from the movement of the user, process the data and as a result, provide
the user with the information about how many steps they have walked in a day and also converts
the data into calories burned.

4.6 Agriculture and food industries (Hydroponic Vertical farming)

Smart sensors in these two fields are still in the testing stage. These innovative connected sensors
collect, interpret and communicate the information available in the plots (leaf area, vegetation
index, chlorophyll, hygrometry, temperature, water potential, radiation). Based on this scientific
data, the objective is to enable real-time monitoring via a smartphone with a range of advice that
optimizes plot management in terms of results, time and costs. On the farm, these sensors can be
used to detect crop stages and recommend inputs and treatments at the right time. As well as
controlling the level of irrigation.

The food industry requires more and more security and transparency, and full documentation is
required. This new technology is used as a tracking system as well as the collection of human data.

Fig 4.2: Impact of Industry 4.0

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CHAPTER-5

Challenges inherent in adopting an industry 4.0

5.1 Technological Challenges:

• Data security issues are greatly increased by integrating new systems and more access to those
systems.

• A high degree of reliability and stability are needed for successful cyber physical
communication that can be difficult to achieve and maintain.

5.2 Social Challenges:

• Maintaining the integrity of the production process with less human oversight could become a
barrier.

• Loss of high paying human jobs is always the concern when new automation are introduced.

• A systematic lack of experience and manpower to create unemployment these systems and
general lieutenants from stakeholders and investors to invest heavily in new technologies.

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CHAPTER-6

Applications and benefits of Industry 4.0

6.1 Customer need and Revenue Growth

• Industry 4.0 will also drive revenue growth. Manufacturers’ demand for enhanced
equipment and new data applications, as well as consumer demand for a wider variety of
increasingly customers products, will drive additional revenue growth.

• Industry 4.0 allows for a fast response to customer needs.

6.2 Employment
• Industry 4.0’s impact on German manufacturing, it was found that the industry 4.0 will
lead to a 6% increase in employment during the next 10 years.

• Growing use of software, connectivity, and analytics will increase the demand for
employees with competencies in software development and it technologies, such as
mechatronics experts with software skills.

6.3 Productivity and Production process

• Industry 4.0 will be incorporated by more companies boosting productivity across all
manufacturing sectors and higher productivity gains will be achieved.

• Conventional manufacturing cells will be replaced by fully automated, integrated

production lines.

• Physical prototypes will be reduced to an absolute minimum.

• Manufacturing processes will increase in flexibility and allow the economic production
of small lot sizes.

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CHAPTER-7

Conclusion

 Industry 4.0 will affect our identity, our sense of privacy, are notions of ownership, hour
consumption patterns, the time we devote to work and leisure, and how we nurture the
relationship.

• There should be a coexistence between technology and humans. The technology should
support humans and only handle the complex situation in manufacturing that is almost

impossible for humans to do .

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CHAPTER-8
References

• Bai, Chunguang; Dallasega, Patrick; Orzes, Guido; Sarkis, Joseph (1 November 2020).
"Industry 4.0 technologies assessment: A sustainability perspective". International Journal of
Production Economics. 229: 107776. doi:10.1016/j.ijpe.2020.107776. ISSN 0925-5273.
S2CID 218941878.

• Colombo, Armando W.; Karnouskos, Stamatis; Bangemann, Thomas (2014). "Towards the
Next Generation of Industrial Cyber-Physical Systems". Industrial Cloud-Based Cyber-
Physical Systems: 1–22. doi:10.1007/978-3-319-05624-1_1. ISBN 978-3-319-05623-4.

• Philbeck, Thomas; Davis, Nicholas (2018). "The Fourth Industrial Revolution". Journal of
International Affairs. 72 (1): 17–22. ISSN 0022-197X. JSTOR 26588339.

• UK Gov Department for Business, Energy & Industrial Strategy (11 June 2019). "Regulation
for the Fourth Industrial Revolution". GOV.UK. Retrieved 18 November 2021.

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