TS012- Textile Industry 4.0

Textile Industry 4.0
Vaibhav Chaudhari
Department of Textile Technology
Veermata Jijabai Technological Institute, Mumbai,India
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.

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

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)

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.


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