Industry 4.0 provides an integrated perspective in a digitized setting wherein cyber and physical world views are integrated. It also provides an opportunity to make manufacturing smart, sustainable .and long term basis.

1. INDUSTRY 4.0 : IMPRESSIONS, INSIGHTS &
IMPLICATIONS
S G DESHMUKH
ABV-INDIAN INSTITUTE OF INFORMATION TECHNOLOGY & MANAGEMENT,
GWALIOR
National Conference on Advances in Mechanical Engineering
(NCAME - 2016).
B.S. Anangpuria Institute of Technology and Management
12 MARCH 2016

2. Key talking points ..
• What is mechanical engineering?
• Today’s manufacturing – need /imperative
• Impressions
• Connected world
• Device vis-à-vis human being
• Service oriented architecture
• Insights
• Various implications
• Manufacturing & control
• Maintenance
• Workforce

3. Where is Mechanical Engineering?
• Its presence?
• Its form?
• Its content?
• Relationship with other disciplines?
• Mechanical engineering is the discipline that applies the principles
of engineering, physics, and materials science for the design, analysis,
manufacturing, and maintenance of mechanical systems. It is the branch
of engineering that involves the design, production, and operation of
machinery.
• Source: https://en.wikipedia.org/wiki/Mechanical_engineering

4. What are the Advances in
Mechanical Engineering ?
• Theme of the conference !
• Mechanical Design
• Manufacturing Sciences & IE
• Thermo-fluids
Mechanical Engineering advanced by the developments in
other engineering

5. Let us get back into History !!
Evolution ..
First Industrial
revolution
Introducing mechanical
production machines
powered by water and
steam/ Mechanization
Second Industrial
revolution
Introducing mass
production
lines powered by
electric
energy
Third industrial
revolution
Through the use of
electronics
and IT further
progression in
autonomous production
Fourth Industrial
revolution
Based on cyber-
physical-
Systems
Mass customization ?
Steam Power/Mechanical
Energy
Electrical Energy ICT ? IOT
End of 18th Century Start of 20th Century Early 70’s 2012-

6. Let us get into present:
Smart regime..
Smart
Phones
Smart
Homes
Smart
Vehicles
Smart
factory
Smart City
Technology
Push
Market
Pull

7. Observations..
• Today’s customer- Hyper-demanding
• Today's world : Hyper-connected
• Today’s manufacturing- Hyper- Smart and Sustainable
• Internet of Things (IoT) : Network of physical objects—
devices, vehicles, buildings and other items embedded with
electronics, software, sensors, and network connectivity—
that enables these objects to collect and exchange data.
source-https://en.wikipedia.org/wiki/Internet_of_Things

8. Insights ..1..
•Manufacturing – wealth generator
•Across the globe, governments, industrial federations,
and corporations have recognized the significance of
creating their own added value through production.
•One cant compete unless manufacturing is strong !
•Why “Make in India”?

9. Impression 1:
Ubiquitous Information Availability
• Global markets are demanding more flexibility and productivity
• Resource consumption has to be minimized.
• Progress in in communication, sensor and production technologies
opens new sustainable and competitive ways of innovation,
production and consumption
• More and faster information will optimize resource use, shorten
lead times, increase productivity and allow the automated
production of smart products
• Information in any form, any time, any device

10. Insights ..2..
• “Information that drives the next century’s structural shift in
manufacturing.”
• Making real-time information available:
• when it is needed,
• where it is needed
• and in the form it is needed throughout the Manufacturing
ecosystem

11. What is Industry 4.0
Synergistic combination of industry and the
current Internet of Things (IoT) technology is
Industry 4.0
An initiative for Smart Manufacturing !

12. Industry perspective ..
Industry 4.0 :
Challenges & solutions:
• Status paper by Deloitte (2014)
• http://www2.deloitte.com/content/dam/Deloitte/
ch/Documents/manufacturing/ch-en-
manufacturing-industry-4-0-241

13. Disruptive technologies behind
Industry 4.0
• Analytics and Big Data
• Mobile technology
• AI & Robotics
• Cloud Computing
• Social networking

14. The traditional Factory
• Monolithic
• Hard wired
• Centralized
• Fixed locations
• Low skill set for labor

15. Smart factory ..at the heart of
Industry 4.0
• Smart Manufacturing Intelligence
• Understanding of the manufacturing process through modeling and analysis
• Ability and agility to observe and take action on integrated patterns of operation through networked data, information,
analytics, and metrics
• Dynamic management of energy and material resources
• Smart Manufacturing Practice
• Generating and coordinating use of sensor-based, data-driven manufacturing intelligence
• Applying integrated performance metrics based on real-time action
• Reusing, and scaling integrated practice using a common infrastructure (both cyber and physical)
• Smart Manufacturing Execution
• Dynamic coordination of decision/action workflows in heterogeneous environments without losing control of state
• across different time constants and seams, including supply chain
• multi-vendor discrete, continuous, operational and human/social applications
• Applications that can share data and data that can share applications and devices

16. Scheme of things
16
Internet of things
Digitized
Production
Smart products Smart factory
…Digitized services
Product
innovation
Process
innovation
Intelligent
systems
Cloud and AI
based
networking

17. Impression 2:
Siemens view of Industry 4.0
• Industry 4.0 is an interesting initiative introduced by
German companies such as Siemens with a motive of
enhancing German competitiveness in manufacturing.
• http://www.totallyintegratedautomation.com/2014/07/smart-
manufacturing-industry-4-0-whats
• https://www.youtube.com/watch?v=HPRURtORnis

18. Insights ..3..
• New organization of value chains.
• On the one hand through vertical network distribution, product
development and services.
• On the other hand through horizontal network distribution
between supplier, contractor and customer.
• Value chains generate hybrid products (Part material part
service part knowledge)
• Manufacturing : Service orientation ?
18

19. Implications ..1..
Various connotations
• Smart materials
• Smart Controls
• Smart manufacturing processes
• Environment friendly operations
• Closer to customer and pulled by smart customer trigger

20. Implications ..2..
Change in orientation
• From compartmentalized to interdisciplinary mode
• From pure manufacturing to service +Manufacturing
• From producer to customer
• From push to pull
• From Reactive to Responsive

21. Implications ..3..
Networking
• It presents a big opportunity to have an enterprise view of suppliers,
distributors and companies in the entire value chain where there will
be a strong degree of coupling between Cyber and Physical world!.
• The entire manufacturing facility can be visualized and controlled
through apps available on smart devices!- remotely controlled yet at
the ground level .
• Benefits : Reduction in manufacturing cycle time and at the same time,
the vision is to have mass customization affordable with intimate
knowledge about customer!.
• The manufacturing will be smart, social and sustainable !

22. Implications ..4..
Manufacturing & Engineering
Manufacturing
• Replacing repettitive/dull monolitic human work in a drastic manner
• Synegistsic man-machine collaboration in real time
• Conectiviuty of devices/human
• Technology : 3D – Printing/Virtual Reality (training / support )
• Remote control of production equipment
Engineering
• Virtul reality : Computer based simulation, gaming
• AI support aided by social networking
• Technology platform: cloud-computing and crowd-sourcing
• Innovation & Creativity based
22

23. Implications ..5..
Maintenance & Manufacturing control
Maintenance
 Remote controlled maintenance
 Designed for maintenance
 Wen enabled support for decision making
 Technology support: Exensive use of sensors to monitor the state of
equipment
Manufactirng control
 Integrated approach
 Seamless/ paperless logistics
 Tractability / traceability of products and parts- RFID
 Digital memory of the product
 Optimisation of production with BIG DATA/Analytics
 Social media 23

24. Implications ..6..
Quality of workforce
• Rapid change of necessary skills/capabilties
• Creation of new jobs for high skilled workers in the areas of planning,
configuration and maintenance of the new technologies
• Expansion of low-skilled work through the use of robots and assisting
systems
• Ergonomical improvement through the use of robots
• Extensive control and monitoring of workers behavior and performance
• Increased expections regarding individual flexibility
24

25. Implications ..7..
For educational institutes
• Institutes must develop strong linkages with industry to understand and
appreciate and gear themselves for meaningful R&D in collaboration with
industry
• The discipline boundaries such as electrical, mechanical etc must vanish so as
to appreciate and understand integrated solutions as desired by the industry
• Digital manufacturing is going to revolutionize our view of manufacturing and
consequent need to develop trained manpower for the same. This calls for
strong curriculum review.
• Mechanisms to upgrade skills need to be established in conjunction with
industry. Online courses forums such as Mooc, need to be aggressively
utilized.

26. Industry 4.0 in summarized form
• Digitalization and increased integration
» The horizontal value chain and vertical connectivity of a company
• Autonomous, self-organizing production units
• Intelligent products actively support the production process
• Creation of innovative business models
• Industry 4.0 provides the framework

27. My post on Linkedin about industry 4.0
• https://www.linkedin.com/pulse/industry-40-implications-technical-
institutes-sanjeev-deshmukh?trk=pulse_spock-articles

28. Where is Mechanical Engineering?
• Its presence? Everywhere !!
• Its form? Is embedded into others !!
• Its content? Both digital and analogue and SMART !
• Relationship with other disciplines? Interdisciplinary and
cutting across boundaries

29. SMART..
• Sustainable
• Meaningful
• Achievable
• Relevant
• Tractable
• “Smart ’ - Investments in human and social capital and traditional
Physical and modern IT infrastructure is done with a wise
management of natural resources to add value

30. Industry 4.0 on youtube
• Industry 4.0- Integrated industry reaches the next level (4.01 minutes )
• https://www.youtube.com/watch?v=ccB6e18VwsQ
• Furniture production on the way to Industry 4.0 (3.53 minutes)
• https://www.youtube.com/watch?v=KUKl-c5uWbM
• Industry 4.0 in the Volkswagen group (5.12 minutes)
• https://www.youtube.com/watch?v=JTl8w6yAjds

31. Code-n-Conference on Industry 4.0
• Industry 4.0 : Tapping the full potential of future manufacturing (
Hour 25 minutes) – Proceedings of the conference
• https://www.youtube.com/watch?v=wxO7NOWF39o

32. Acknowledgement
• Dr Kota Harinarayana (Chairman, BOG, IIITDM Jabalpur)
• Mr Baba Kalyani (CMD, Bharat Forge )
• Prof Puneet Tondon (IIITDM, Jabalpur)
• Mr Ashutosh Chinchalkar (CMD, Smart Controls, Gwalior)
• My special thanks to Prof Lajpat Rai, and Prof JP Subrahmanyam

33. Thank you
deshmukh.sg@gmail.com