This paper helps to connect almost everything from machines to humans through cloud by showing drastic and dramatic improvements to improve business efficiency and also protecting and regenerating natural environment by bringing forward better asset management techniques.
International Journal of Management (IJM) Volume 11, Issue 2, February 2020, pp 132–140, Article ID: IJM_11_02_014 Available online at http://www.iaeme.com/ijm/issues.asp?JType=IJM&VType=11&IType=2 Journal Impact Factor (2020): 10.1471 (Calculated by GISI) www.jifactor.com ISSN Print: 0976-6502 and ISSN Online: 0976-6510 © IAEME Publication Scopus Indexed INDUSTRY 4.0 SOLUTIONS – A PATHWAY TO USE SMART TECHNOLOGIES / BUILD SMART FACTORIES Dr N Venkateswaran Professor, Department of Management Studies, Panimalar Engineering College, Chennai, India E-mail: profvenkimba2019@gmail.com ABSTRACT Today Industry 4.0 moving in faster pace across sectors through newer approaches which helps to migrate entire society and human body Technologies like additive manufacturing, robotics, quantum computing, internet of things [IoT], nanotechnology and autonomous vehicles, machine learning are under the umbrella of Industry 4.0 solutions moving in exponential rate This paper helps to connect almost everything from machines to humans through cloud by showing drastic and dramatic improvements to improve business efficiency and also protecting and regenerating natural environment by bringing forward better asset management techniques Worldwide companies looking for smarter work by making themselves more competitive and sustainable through infrastructure investment by expanding their business platforms by transforming themselves through digitally enabled technologies Digital transformation is every key motive to survive in Industry 4.0 era which help industries to attain competitiveness and at the same allowing them to have an ability to take optimal decisions across all the phases of their activities Industry 4.0 and IoT have some tangible benefits with proven ROI Keywords: IoT, smart products, physical security systems, digital twin, digital intelligence Cite this Article: Dr N Venkateswaran, Industry 4.0 Solutions – A Pathway to Use Smart Technologies / Build Smart Factories, International Journal of Management (IJM), 11 (2), 2020, pp 132–140 http://www.iaeme.com/IJM/issues.asp?JType=IJM&VType=11&IType=2 INTRODUCTION Every industry is driving the next industrial revolution as both a lead operator and lead supplier of Industry 4.0 solutions Today Industry 4.0 moving in faster pace across sectors through newer approaches which helps to migrate entire society and human body http://www.iaeme.com/IJM/index.asp 132 editor@iaeme.com Dr N Venkateswaran Technologies like additive manufacturing, robotics, quantum computing, internet of things [IoT], nanotechnology and autonomous vehicles, machine learning are under the umbrella of Industry 4.0 solutions moving in exponential rate Smart technologies using Industry 4.0 solution allows firms digitally enabled automated self-optimized production capability including deliveries without human interventions These firms establish value networks and it should be decentralized in nature and their manufacturing or transport facilities should take autonomous decisions instantaneously [2] With huge automation portfolio as a pathway and roadmap and an abundance of human resource production experience across plants worldwide irrelevant of the sectors, modern sectors can now offer leading automation and manufacturing solutions – migrating from single-piece to high-volume production by enriching their infrastructural base Industry 4.0 allows delivering of excellent and prominent benefits which makes firms to initiate smart factory Combination of digital technologies with automated solutions makes every manufacturing sector a major jump start and newer ways of growth strategies for every sector It is a right time for every time and it is crucial also for every companies who should have a vision to capitalize their investment on smart manufacturing which make them key competitive advantage In the VUCA complex world, radical innovations happened across sectors for sustainability Better business models with dynamic characteristics developed continuously which allow them to attain complementary competency For example, automobile manufacturers keep improving their existing value chain by merging through interdisciplinary partnerships with different service providers, suppliers and cross industry disciplines since closer horizontal partnerships are not restricted in the field of innovation This approach allow them to find out better and newer solutions for produce customizable goods according the changing needs in customer expectations with faster delivery and also in effective manner Industry 4.0 applications shows unexpected quantitative benefits over the next coming years from the investments planned across the sectors Across the sectors they continuously anticipate an increase in the average efficiency of 25% through digitalized economy This shows an annual increase of 4.5% One fourth of the firms see greater potential in their existing operations The improvements may be in reduction of wastages in process, quality loss, more flexible and coherent in making processes and converting themselves in focusing on core areas in individual value chain By 2025, 85% of the firms will achieve digitization as high degree on their manufacturing products and services This percentage will tend to increase more than five times from current 9% to 45% Companies wish to excel internationally should take this has a major challenge The existing business models across sectors will become more data centric, much efficient and more customer focused because of improvement in connectivity and usage of analytical/data abilities across processes The two important qualitative benefits of Industry 4.0 should be more improve planning and control abilities and greater customer satisfaction Basically the term "smart" means combining tangible or intangible goods using digital systems Through smart applications and technologies firms able to communicate intelligently with each other, allowing firms to generate value added services for their customers continuously The goods and services sometimes expand their original range of services many times over The intelligent factory or smart factory is the recent heart of Industry 4.0 solutions Their aim is to establish autonomous production through which firms resources [people, machines, plants and products] communicate independently with each other called cyber-physical systems make production more flexible and efficient This establishment makes firm possible http://www.iaeme.com/IJM/index.asp 133 editor@iaeme.com Industry 4.0 Solutions – A Pathway to Use Smart Technologies / Build Smart Factories enough to implement individual customer wishes through better product customization at minimum costs with better quality efficiency that were not been possible in during previous revolutions called mass production Artificial intelligence and machine learning are currently driving smart manufacturing but still human input is essential This smart manufacturing requires human computer interaction which they provide direction and control apart from overseeing technology Technology empowers human workforce which is a requirement of many industries to migrate themselves to build smart factories and has a growing role across sectors This solution helps to connect almost everything from machines to humans through cloud by showing drastic and dramatic improvements to improve business efficiency and also protecting and regenerating natural environment by bringing forward better asset management techniques There is an option available for sectors is data-driven manufacturing to manufacturers allowing them to access all types of data in various forms and sizes from smallest shops to the largest plants It is simpler to implement, scalable and affordable Industry 4.0 also referred as IIoT [Industrial Internet of Things] or smart manufacturing, currently married physical production and operations with smart digital technology, machine learning, and big data to create a healthy and better connected digitally for companies which focus on smart manufacturing and modern supply chain management practices [12] With the evolution of hybrid architectures, each sector increases their potential in resource efficiency, effectiveness and flexibility in their approaches Worldwide companies looking for smarter work by making themselves more competitive and sustainable through infrastructure investment by expanding their business platforms by transforming themselves through digitally enabled technologies Digital transformation is every key motive to survive in Industry 4.0 era which help industries to attain competitiveness and at the same allowing them to have an ability to take optimal decisions across all the phases of their activities Industry 4.0 and IoT have some tangible benefits with proven ROI In the recent scenarios all manufacturing systems are harnessing the full array of new and emerging technologies Using internet as foundation base every organization link their existing equipment, their sensors, and analytical tools and people in ever more intricate and resourceful ways Big data, robotics, machine learning, artificial intelligence, augmented reality, 3D printing, predictive analytics all these things and more are now converging slogans dictated by every sectors [10] And with the heightened level of control and oversight that they bring, firms can now build a ―digital twin‖ of their existing core process, and so allowing firm to optimize their core business performance by creating a healthy working atmosphere of their existing physical object or process PRACTICAL IMPLICATION OF INDUSTRY 4.0 SOLUTIONS The practical implication of this research is to examine the current challenges and opportunities that are more relevant in implementation of Industry 4.0 More companies today looking for transition to attain competitive advantage and most importantly their security concerns in managing their business are in compulsion over decades all are rewriting, destabilizing themselves to become smart by connecting their process, product and service to improve economies within the society Industry 4.0 is a key solution for these business concerns which will create rapid progress in sustainability in all domain areas of an organization Recent manufacturing methodological practices are becoming more complex and dynamic especially non-linear patterns in data, data driven approaches are becoming ever more critical http://www.iaeme.com/IJM/index.asp 134 editor@iaeme.com Dr N Venkateswaran Invention of connected devices offering new opportunities with self-configuring automations allows a one step forward change in productivity measures [9] It is must for smart enabled industries to identify and find newer tools which helps them to transform their existing data into models which allows them to predict, detect, classify and forecast manufacturing operations more efficient by finding ways to real competitive advantage ORIGINALITY/VALUE Most of the researchers across various domain and technologies contributed many research papers on Industry 4.0 solutions but this manuscript provides an alternative path on by measuring how industry 4.0 solutions gives business firms by identifying there suitable technologies by converting themselves to produce smart product and services Also currently there are wide spread manufacturing technologies solutions available across globally This paper suggests how these technologies are supportive for business environment Increasing importance of Industry 4.0 offers combination of digitization which allows manufacturing firms not only link their internal production facility but also link entire production facility Many industries over the year are migrating themselves by building paradigm shift towards Industry 4.0 solution because of the following reasons[6] First, Industry 4.0 reduces Mean Time to Repair [MTTR] which enables predictive maintenance of components and machines Most of the legacy devices across firms migrating towards smart devices helps manufacturing process to identify detection of faults and reduction in repairing time User dash boarding an evolving concept of cloud integration benefit user in analyzing fault logs and pattern of faults, auto job assignment via E-mail Multiple legacy devices are easily communicated via IoT Protocol gateway LITERATURE REVIEW Industry 4.0 is recently a new booming topic by everybody across the world a comprehensive overview of the state of the emerging industrial revolution is essential to investigate on Scopus database Most of the researchers across global shown recently a major interest in this topic The search was refined considering only articles As an author we referred more than 150 published articles since 2014 Since 2017, there is a growing trend of publications on these issues This strong interest is certainly due to continuous changes happening across sectors due to automation, modern methodological practices purely through smart manufacturing both from a research and business point of view Personal flexibility with respect to work time, work contents, workplaces and mindsets are prerequisites competencies for an agile production, to respond quickly to market need and environmental situations In addition, today and future managers need the ability to transform their management and leadership styles from power-driven to value-driven, as the teams of the Smart Manufacturing and Industry 4.0 are currently diversifying themselves all in geographical location, culture, and education According to Stephen Gold, President and CEO, MAPI, US gross domestic product is 11% of the manufacturing output but its total economy is three times more than it total value chain Reasons for this complete digital transformation allows US companies to be more competitive and continuous research and development provides them excellent insights for their manufacturing leaders which they propel their digitalization journey irrelevant of their existing state of their operations According to MGI report, ―The Internet of Things: Mapping the Value Beyond the Hype,‖ predicted that the application of the Internet of Things in the manufacturing context alone—in http://www.iaeme.com/IJM/index.asp 135 editor@iaeme.com Industry 4.0 Solutions – A Pathway to Use Smart Technologies / Build Smart Factories other words, using sensors to bring intelligence to each piece of production equipment on the factory floor to optimize their collective use—would increase manufacturing productivity by 10 to 25 percent, with the potential to create as much as $1.8 trillion in new value per year across the world’s factories by 2025 Many market research firms estimate smart manufacturing / technologies will reach greater heights over the next – 10 years with hundreds of billions of dollars range Grand View Research predicts reach USD $400.3 billion by 2026, Future Market Insights ―420B‖ by 2029, Statistica ―$482B by 2023‖, Markets and Markets ―$205B by 2022‖ and Orbis Research ―$595B by 2024‖ Manufacturing output may be 11% of U.S gross domestic product, which is three times ahead of its total value chain for the economy Digital transformation increase manufacturing's importance and competitiveness which provides a modified research approach and insights Many manufacturing leaders across sectors already propel their digitalization journey, regardless of the current state of their operations According to Vodafone, companies ―adopting the IoT‖ brings average cost savings for industry of 18 percent, with nearly 10 percent of IoT adopters reducing their costs by over 25 percent, in addition to realizing other benefits including: process efficiencies; speed and agility in decision making; better customer service; consistency of delivery across markets; transparency/predictability of costs; and better performance in new markets McKinsey has subsequently developed a ―Digital Compass‖ diagnostic tool to guide companies in their adoption of Industry 4.0 and has worked with the Digital Manufacturing Design and Innovation Institute which allow the firm to evaluate their actual returns through realizing from digital manufacturing implementations According to US Department of Commerce survey more 95 US manufacturers and vendors found that smart manufacturing allow firms and provide $63 billion dollars cost reduction annually This represents on an average and approximate reduction of 4.5% reduction in shop floor production cost Techniques such as seamless digital transformation, monitoring and sensing, advanced analytical data save many manufacturers in excess of $20 billion annually According to a Research & Markets report, in 2014 global manufacturing market was 20 billion dollars and it will show progressiveness by an increase of 13.5% per year till 2024 The major reason for these drivers of development is mainly because of industrial process automation and every sectors are looking for integrated analysis and design solutions Every industries in the recent platforms keen on reducing costs, continuously improving and launching through speeding up their product development life cycles, migrating themselves towards simulation applications through cloud based platforms The analysis pointed out that 53.2% of the analyzed publications refers to engineering issues, 29.2% refers to communications issues, and 17.6% refers to business process management Analyzing the 150 articles found, the search was more refined using seven specific keywords that characterize ―Industry 4.0‖ as detailed below: Cyber-physical systems Big data or digitalization or digital Automation or artificial intelligence or robotics Additive manufacturing or 3D printers Simulation/augmented/virtual reality Industry 4.0 moves from potential to reality open standards are more crucial for successful deployment 4.0 solutions are highly dependent on connectivity – technically as well as organizationally within the entire value creation process of every firm connecting suppliers http://www.iaeme.com/IJM/index.asp 136 editor@iaeme.com Dr N Venkateswaran and manufacturers by breaking the wall of existing technology boundaries by collaborating with research organizations, OEMs, manufacturers, and others The application of IoT is projected to generate $1.2 to $3.7 trillion of value globally by 2025, in four primary forms: 1) operational efficiency; 2) predictive and preventative maintenance; 3) supply chain management; and 4) inventories and logistics.8 While manufacturers’ IoT implementations often address multiple facets of these manufacturing processes, the following paragraphs provide specific examples of IoT being used to facilitate each of these four types of manufacturing processes Almost all firms are almost working under real-time conditions by slowly reengineering existing in-house production process to be radically optimized by initiating flexible production systems Nowadays, production advantages are completely changed and it has not limited solely to one-off production conditions, but it can get optimized through adoption and self-organizing production units by enriching every operator to look up on multiple processes to establish global network standards Today, in an Industry 4.0 smart factory, all manufacturing machines are integrated through collaborative community This setup requires use of advanced prediction tools for factories, so that data within data warehouse / database can be systematically processed into information to overcome / manage uncertainties allowing firms to make more informed decisions [1] Industry 4.0 describes different meaning — basically Information Technology (IT) driven—changes in manufacturing systems These tremendous developments allowing firms not only to have technological advancements but also versatile organizational implications [4] The principles of IoT or ―Internet of Things‖ allows factory planners to embrace the vision without traditional hierarchical ways where smart objects have capable of selforganizing for a specific task through proper interaction based on semantic services [5] Hermann, Pentek and Otto [3] and their co-authors, identified four basic tools needed to implement Industry 4.0 within a company by making research and analysis from different 50 studies Most of the tools searched with keywords like CPS, IoT, the Internet of Services and the Smart Factory The tools chosen by the authors are all comprehensive categories, and they not specify technical tools needed to operate the CPS (e.g., sensors) To establish a smarter working environment using Industry 4.0 solutions Wang et al [7] discussed in his research work identified four layers, which can contribute to a closed-loop system: (1) a resource layer; (2) an industrial network layer; (3) a cloud layer; and (4) supervision and control terminal layer These layers allows to link people within the smart factory, In addition, Monostori [6] states that cyber-physical production systems not follow the traditional automation model since higher levels of the hierarchy are decentralized DIGITAL MODEL IN SMART TECHNOLOGIES Adoption of digital model is key strategy in the modern manufacturing process in production workflows In the traditional methodologies of product development from inception to deployment takes longer time whereas through digitally enabled smart technologies collaboration between teams improved through agile way and the prototype development assimilated quickly into production and in faster mode the end product will hit the market with better product efficiency [2] Through Industry 4.0 solutions firms create end-to-end and cross functional research and development allowing them to operationalize their digital innovation through smart technologies like AI, 3D printing, digital twin, cloud computing, high-performance computing, quantum computing, wireless connectivity, advanced sensor technologies, computer aided design (CAD) and engineering (CAE) software at every stage of http://www.iaeme.com/IJM/index.asp 137 editor@iaeme.com Industry 4.0 Solutions – A Pathway to Use Smart Technologies / Build Smart Factories product and service development This newer approaches prefers firms to unlock new revenues by closer interaction with the stakeholders as whole Industry 4.0 indicates that lower and middle tier staff may be subjected to be less required with the time as smart machines will replace that role and while the new skill requirements in terms of digital supervision will still exists This will prompt the change roles from machine operators to supervisory roles [5] In the digital world, based on customer requirements all inbuilt monolithic process based applications within organizations are shifting their manufacturing processes towards personalized, automated and localized value chains This shift of technology definitely provides a greater personalized infrastructure for the firms to sustain competitive advantage among competitors The following business models analyze and interpret better results for every industrial survival to benchmark their product and services continuously Collaborative robots to augment workforces Cloud robotics & APIs give manufacturers greater control Robotics-as-a-service make robotics viable for smaller manufacturers 5G & Multi-access Edge Computing (MEC) help keep factory workers informed Edge computing to see new use cases Cybersecurity will be given greater priority Digital twins will be employed more widely across manufacturing and the supply chain Additive manufacturing will be used to create final products Wearables will become commonplace on the factory floor SMART TECHNOLOGY STANDARDS Every factory has smart manufacturing vision to succeed, a series of standard protocols will be indispensable to allow factories, machines, and products made by vendors from all over the world to communicate and interact with each other and to ensure solutions can be used in any country Two key issues standardization must address are ensuring interoperable interfaces between solutions from different manufacturers; and establishing open standards, which are essential for the emergence of open, flexible, and dynamic manufacturing features all because of innovative ecosystems which spans different manufacturers from different countries and continents A number of risks arise if the international community fails to achieve standardization around Industry 4.0 First, the inability of sensors, machines, and software produced by a variety of different global vendors to seamlessly exchange data, information, and intelligence in real-time would leave the smart manufacturing vision stillborn [11] If no international standards or universal solutions not properly followed across sectors providing interoperability between different systems, individual companies run a major risk of suffering technological lock-in Several key private-sector-led consortia are involved in smart manufacturing standards development especially countries like United States who are the chief among Industrial Internet Consortium (IIC) The IIC spans a number of fields including energy, healthcare, manufacturing, the public sector, and transportation The IIC has two key objectives: 1) Promoting innovation through the establishment of use cases and test beds to enable rapid testing of ideas and technologies in real-world applications; and 2) Facilitating the development of the reference architectures, frameworks, and open standards required for the interoperability of industrial systems http://www.iaeme.com/IJM/index.asp 138 editor@iaeme.com Dr N Venkateswaran FUTURE DIRECTIONS OF INDUSTRY 4.0 Industry 4.0 solutions expecting and newer version of Industry 5.0 in near future which may happen has a natural progression for every industry This solution may undertake modern manufacturing process where this reintroduce ―human touch‖ component called Colloborative robots or ―Cobots‖ may introduce across sectors and it may be more autonomous and work along with our human colleagues by helping them in complete their work [13] It would not mean that Industry 4.0 [digital and automated technologies] may become disruptive but it may use as a primary driver for development along with 5.0 delivering more personalized experience and offering and also to increase efficiency and precision to the users The pure success or failure of smart technology and Industry 4.0 revolution highly depend on contribution of human capital in their own way which may pave a right path in their success and productivity As we represent earlier human capital alone represents collective value of Smart technologies and Industry 4.0 revolution’s competencies, knowledge and skills It is must for industries to renewal the better ways in identifying sources of creativity and innovation which imparts industries to move towards Smart Manufacturing and Industry 4.0 revolution, and transition in making ability to change Recent Industry 4.0 solutions making workers within firm who need to stimulate physical, docile forms of tangible capital, inert forms of material and equipment Improving Human capital is an essential asset in surviving in Smart Manufacturing and Industry 4.0 revolution and modern managers today facing it as greatest challenge in their organizations CONCLUSION Industry 4.0 concept known worldwide and it may be the latest hot topic of discussion for past five years across sectors Industry 4.0 production concepts and their deployment is half-way paths for many enterprises who are all still in infant stages and industries with an idea of making themselves to be digitally transformable enterprises / smart enterprises need to gradually reengineer their existing / legacy equipment and solutions without affecting their existing production set-up The key element to deploy smart factory requires compound talents and multi-field cooperation is required for every firm The research shows to implement and establish smart factory / smart technology integration of information technology is not alone sufficient but also to include traditional disciplines such as control theory, materials and energy With the advancement of big data technology to improve product quality, increase production efficiency, reducing energy consumption all firms uses data based virtual manufacturing mode part of intelligent manufacturing and also based on big data which leads major revolution on traditional industry It is must for every industry to overcome many challenges by managing systematic transition on Industry 4.0 solutions by pushing themselves through research and experimentation through identification of relevant fields especially on privacy, security and employment This strategy is applicable both for large corporation and public sectors and it is a promising picture and should be truly revolutionary Shop 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.. giving consumers exactly what they want http :// www.iaeme.com/IJM/index.asp 139 editor@iaeme.com Industry 4.0 Solutions – A Pathway to Use Smart Technologies / Build Smart Factories REFERENCES... requires use of advanced prediction tools for factories, so that data within data warehouse / database can be systematically processed into information to overcome / manage uncertainties allowing