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PROCESS AUTOMATION THE JOURNEY TO INDUSTRY 4.0 IS NOT OVER YET
Despite reports of Industry 5.0 and 6.0 emerging, there’s still work to be done in the quest for Industry 4.0, according to Marta Pieńkowska, Product Owner at STX Next
he use of data to support outcomes in manufacturing has increased exponentially in recent years. Yet according to research from the World Economic Forum from December 2022, just 39% of manufacturing leaders said that they had successfully been able to scale data- driven use cases beyond a production process for a single product.
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Despite this reality, mentions in the media of Industry 5.0 or 6.0 have already started to appear. These calls are largely speculative and certainly premature. While the concept of Industry 4.0 has been around for some time, there has yet to be a widespread adoption of its core principles. There is no doubt that the technology that has been introduced by manufacturers to power Industry 4.0 can greatly transform the way products are analysed, designed and produced. However to fully capitalise on this technology’s potential, manufacturers and their teams must first understand and embrace the design principles that are needed to make Industry 4.0 a reality.
Industry 4.0 means technology plays a part in the development process and predicts challenges ahead
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goals, before assessing the quality of your data by auditing and analysing your current systems, processes and assets. There are a number of core design principles that provide a framework for creating a more sophisticated and efficient production process. 1) Communication is key
Introducing
At the core of Industry 4.0 is the interconnectivity and automation of
The needs of manufacturers are naturally varied and unique, with no one-size-fits-all approach to growth or technology adoption. Implementation of Industry 4.0 will therefore take time and vary greatly for each business, depending on current levels of adoption and company structure.
There are also several common challenges when it comes to introducing Industry 4.0, such as the cybersecurity implications that must be considered when adding interconnectivity between systems, or ensuring you have the right skills in place to introduce this new technology successfully.
Realising Industry 4.0 starts with understanding and identifying business
manufacturing through the collection, analysis, and exchange of data between cyber- physical systems. This is called smart communication, which is made possible by advances in machine learning and artificial intelligence. Smart communication provides solutions that can process and analyse large amounts of data at a speed and accuracy beyond human capabilities. These solutions allow for necessary decisions to be made with little or no human assistance. 2) High-quality data
Creating a smart network requires high- quality data, as it influences the network’s intelligence and communication. However, data quality is not the same as data quantity. The volume of unstructured data output is at an all-time high.
It’s crucial to focus on collecting data that’s relevant rather than use any data that is available, since low-quality data can unnecessarily consume valuable resources. 3) Digital transition
Making the switch to Industry 4.0 can’t take place without first completing digital transformation. A transition from analogue to
28 JULY/AUGUST 2023 | PROCESS & CONTROL
digital methods or from digital processes to automated systems
throughout an organisation’s entire
manufacturing
process, so that systems can be interconnected, is one of the first steps and must be done in a considered way. In order to increase reliance on data and base decision-making on it, the process of integrating hardware and software used in production must be thorough and meaningful. 4) Decentralise decision making Enabling machines to make simple, routine decisions based on algorithms is another goal of Industry 4.0. It is a crucial step in achieving a production line that is less labour-intensive and less prone to human error.
Machines that can recognise patterns and identify errors through artificial intelligence can take on a significant workload, freeing up employees to focus on more complex problems that require human intervention. The opportunities that come from successful implementation of Industry 4.0 go well beyond the facilitation and automation of the production process. These technologies can lead to increased productivity, profitability, safety and optimisation, as well as improved record-keeping and traceability. In practice, introducing Industry 4.0 means technology plays a part in every step of the development process and predicts any potential challenges ahead. These principles are fundamental steps in realising the next industrial revolution.
STX Next
www.stxnext.com
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