INDUSTRY 4.0/IOT
HOW TO THRIVE IN THE WORLD OF INDUSTRY 4.0
Darren Hugheston-Roberts says businesses that embrace change can unlock competitive advantages and enhance operational efficiency
make more informed decisions improves efficiency and competitiveness. Industry 4.0 principles therefore offer multiple advantages for manufacturing companies, including enhanced operational efficiency, agility and customisation, accelerated time-to-market, and cost reduction.
Darren Hugheston-Roberts, Senior Manager for Digital and Industry Solutions at TÜV SÜD, outlines how Industry 4.0 technologies are achieving efficiency in the manufacturing sector
ndustry 4.0 is transforming the manufacturing sector, yet this digital transition can also introduce challenges. The fourth industrial revolution is driven by advanced technologies such as automation and robotics, artificial intelligence and machine learning, alongside big data analytics and the Internet of Things (IoT). While manufacturers will face disruption, Industry 4.0 is a growing reality where ongoing digital transformation will push innovation across a wide range of industries. This digitalisation and optimisation impacts manufacturing efficiency and competitiveness. Digitalisation is the foundation of Industry 4.0, enabling manufacturers to optimise operations and drive efficiency gains through predictive maintenance, efficient supply chain management, and real-time quality monitoring. Using advanced analytics and machine learning algorithms, predictive maintenance enables manufacturers to prevent equipment failure by applying proactive corrective measures that monitor equipment health and detect failures in advance. This improves overall equipment efficiency (OEE) by minimising unplanned downtime and maximising equipment uptime. Digitalisation provides real-time visibility and connectivity across the supply chain. As manufacturers can optimise demand planning, procurement, logistics, and after-
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market services, lead times are reduced. Not only is agility increased, but there is also a corresponding improvement in customer satisfaction, including suppliers, business partners and customers.
Manufacturers can also monitor product quality in real-time throughout the production process by using data analytics and IoT devices. Real-time feedback allows for early defect detection and ensures that only high- quality products reach the market. This ensures customer satisfaction and reduces costs associated with rework or recalls. Automation eliminates repetitive and labour-intensive tasks, increasing productivity, reducing errors, and improving workplace safety. Robotic systems enable precise and efficient operations, enhancing production efficiency and scalability. In the meantime, artificial intelligence and machine learning algorithms enable IT and OT systems to autonomously learn and adapt to new needs, while making autonomous decisions to optimise processes, assets and resources, resulting in improved operational efficiency. These changes mean that Industry 4.0 is generating vast amounts of data from sensors, machines, and other sources. Big data analytics allows manufacturers to gain valuable insights into operations, facilitating continuous improvement, cost reduction, and resource optimisation. Using these insights to
14 JULY/AUGUST 2025 | PROCESS & CONTROL
Digitalisation and optimisation modernise processes, reduce waste and improve resource allocation. This increases operational efficiency, allowing manufacturers to produce more with fewer resources, while reducing costs and increasing profitability. Industry 4.0 technologies also improve manufacturing agility by quickly responding to changing customer demands and market trends. Flexible and customisable production processes enable companies to offer personalised products at scale, gaining a competitive edge and fostering customer loyalty.
The adoption of an integrated product life cycle model of people, processes, and systems along the entire life cycle, as well as collecting and analysing data across the product life cycle (design and development, engineering, production, customer use, service and disposal), optimises and shortens development times, and reduces time-to- market. This improves a business’s ability to take advantage of emerging opportunities, stay ahead of competitors, and quickly meet customer needs.
Automation, optimised resource utilisation, predictive maintenance, the reduction of defects, and yield increases all contribute to cost reduction. The elimination of manual and error-prone tasks, minimisation of downtime, and more efficient resource management, means that manufacturers can minimise costs and improve overall profitability. The integration of Industry 4.0’s advanced technologies introduces the potential to transform manufacturing efficiency and competitiveness. Digitalisation and optimisation are enabling manufacturers to streamline operations, take advantage of real- time data insights, and exploit automation, artificial intelligence, and big data analytics.
TÜV SÜD
https://www.tuvsud.com/en- gb/industries/manufacturing
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