Textile
Industry 4.0
Vaibhav Chaudhari
Department of Textile
Technology
Veermata Jijabai Technological Institute, Mumbai,India
Introduction:
Industry 4.0 is the subset of the fourth
industrial revolution that concerns industry. The fourth industrial revolution
encompasses areas which are not normally classified as an industry, such as
smart cities, for instance.
The concept includes:
- Smart manufacturing
- Smart factory
- Lights out(manufacturing) also known as dark factories
- Industrial internet of things also called internet of things for manufacturing
Industry 4.0 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 real-time
both internally and across organizational services offered and used by
participants of the value chain.
Why Industry 4.0 is important?
- It is extremely relevant and increasingly important in manufacturing for a multinude of reasons.
- The reasons why industry 4.0 is important are the benefits. It helps manufacturers with current challenges by becoming more flexible and making reacting to changes in the market easier. It can increase the speed of innovation and is very consumer centered, leading to faster design processes
- Workers can become coordinates at the centre of production, possibly improving the work life balance of employees. Industry 4.0 is sustainable long-term, assisting in finding solutions for any challenges that arises
- So, why Industry 4.0? Because we can help you incorporate it, and all of these benefits, into your current manufacturing, leading you into a sustainable and profitable future.
Terminology:
The term “Industry 4.0”, shortened to I4.0 or
simply I4, originated in 2011 from a project in the high-tech strategy of the
German government, which promotes the computerization of manufacturing. The
term “Industry 4.0” was publicly introduced in the same year at the Hannover
Fair. In October 2012 the Working Group on Industry 4.0 presented a set of
Industry 4.0 implementation recommendations to the German federal government.
The Industry 4.0 workgroup members and partners are recognized as the founding
fathers and driving force behind Industry 4.0. On 8 April 2013 at the Hannover
Fair, the final report of the Working Group Industry 4.0 was presented. This
working group was headed by Siegfried Dais (Robert Bosch GmbH) and Henning
Kagermann (German Academy of Science and Engineering)
The discussion of how
the shift to Industry 4.0, especially digitalization,will affect the labour market is being
discussed in Germany under the topic of Work 4.0.
Design principles and goals:
There are four design principles in Industry
4.0. These principles support companies in identifying and implementing
Industry 4.0 scenarios:
Interconnection: The ability of machines,
devices, sensors, and people to connect and communicate with each other via the
Internet of Things (IOT) or the Internet of People(IOP).
Information transparency: The transparency
afforded by industry 4.0 technology provides operators with vast amounts of
useful information needed to make appropriate decisions. Inter-connectivity
allows operators to collect immense amounts of data and information from all
points in the manufacturing process, thus aiding functionality and identifying
key areas that can benefit from innovation and improvement.
Technical assistance: Firstly, the ability of
assistance systems to support humans by aggregating and visualizing information
comprehensively for making informed decisions and solving urgent problems on
short notice. Secondly, the ability of cyber physical systems to physically
support humans by conducting a range of tasks that are unpleasant, too
exhausting or unsafe for their human co-workers.
Decentralized decisions: The ability of cyber
physical systems to make decisions on their own and to perform their tasks as
automatically as possible. Only in the case of exceptions, interferences, or
conflicting goals, are tasks delegated to a higher level.
Industry 4.0
envisions environmentally-sustainable manufacturing by having green
manufacturing processes, green supply chain management, and green products.
Components of Industry 4.0
“Industry 4.0 is an abstract and complex term
consisting of many components when looking closely into our society and current
digital trends. To understand how extensive these components are, here are some
contributing digital technologies as examples:
- Mobile devices
- Internet of Things platforms
- Location detection technologies
- Advanced human-machine interfaces
- Authentication and fraud detection
- 3D printing
- Smart sensors
- Big data analytics and advanced algorithms
- Multilevel customer interaction and customer profiling
- Augmented reality/ wearables
- Fog, Edge and Cloud computing
- Data visualization and triggered “real-time” training
Mainly these technologies can be summarized
into four major components, defining the term “Industry 4.0” or “smart
factory”:
- Cyber-physical systems
- IOT
- Cloud computing
- Cognitive computing
With the help of cyber-physical systems that
monitor physical processes, a virtual copy of the physical world can be
designed. Thus, these systems have the ability to making decentralized
decisions on their own and reach a high degree of autonomy. As a result,
Industry 4.0 networks a wide range of new technologies to create value.
Principles of Industry 4.0
Based on the components above, the following
are the design principles:
- Interoperability
- Virtualization
- Decentralization
- Real-time capability
- Service-orientation
EFFECTS:
The increasing use of
the Industrial Internet of Things is referred to as Industry 4.0 at Bosch, and
generally in Germany. Applications include machines which can predict failures and
trigger maintenance processes autonomously or self-organized logistics which
react to unexpected changes in production.
Role of big data and analytics
Big data analytics consists of 6Cs in the
integrated Industry 4.0 and cyber physical systems environment. The 6C system
comprises:
- Connection (sensor and networks)
- Cloud (computing and data on demand)
- Cyber (model and company)
- Content (meaning and correlation)
- Community (sharing and collaboration)
- Customization (personalization and value)
Applications:
Optimization: Optimizing production is a key
advantage to Industry 4.0. A smart Factory =containing 100 or even 1000 of
Smart Devices that are able to self-optimize production will lead to an almost
zero down production.
Customization: Creating a flexible market
that is customer oriented will help meet the population’s needs fast and
smoothly. It will also destroy the gap between the manufacturer and the
customer
Pushing Research: The
adoption of Industry 4.0 technologies will push research in various field such
as IT security and will have its effect on education in particular
Challenges facing Industry 4.0:
- Security: Perhaps the most challenging aspect of implementing industry 4.0 techniques is the IT security risk. This online integration will give room to security breaches and data leaks.
- Capital: Such transformation will require a huge investment in a new technology that doesn’t sound cheap. The decision to make such transformation will have to be or CEO level. Even then, the risks must be calculated and taken seriously
- Employment: While it still remains early to speculate an employment conditions with the adoption of industry 4.0 globally it is safe to say that workers will need to acquire different or an all-new set of skills
- Privacy: This is not only the customer’s concern but also the producers. In such an interconnected industry, producers need to collect and analyse data. To the customer, this might look like a threat to his privacy. This is not only exclusive to customers.
References:
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