how mechanical design engineers will be impacted by industry 4.0, what are the challenges and how we overcome them

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Aim :
To understand changing pattern of mechanical industry and its requirements in order to
determine future scope and act accordingly
Purpose :
Mechanical industry have a constant trend of evolving, the recent pandemic is acting as
catalyst and have drastically changed industrial pattern and requirement in very short
period. The faster the understand the quicker we adapt.
Objective :
1. Scope of Mechanical Design Engineering ( 15 minutes)
2. Understanding Industry 4.0 (15 minutes)
3. To understand the changing demand of future industry and how can we adapt
ourselves to match the competitive requirement. (15 minutes)
4. Q&A (15 minutes)
Aim , purpose and objective:

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Scope of mechanical design engineer:
Design engineer :
Design engineer is responsible for development of concept/idea on papers and to convert idea on paper
with actual prototype product including design verification and validation testing with support of testing
team, later guide & train production and service department and push final product to marketing team.
To ensure Calculation, Conceptualization, design, functions, performance, reliability and fitness for
purpose of product and prototype both falls under scope of design engineer. The scope does not end
here, its extended up to verification of mass production tools and production process also.
If design engineer does everything then why we need so many departments?
All these roles and responsibility are too much for a design engineer.
The design engineer do not perform all tasks by himself, the design engineer is usually supported by
Marketing team, New product planning team, Development and purchasing team, Testing team, Quality
team, and Production and process team, and they all work together and support design engineer due to a
simple logic :
No one knows product better than designer himself, Not even customer who created requirement.

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Scope of mechanical design engineer:
How are the task distributed? So many teams so many people?
Too many cooks spoils the dish, right?
To avoid any type of conflict role of every department and its individual is defined under APQP manual
developed by General Motors, Ford, Chrysler and their suppliers in late 1980’s.
APQP procedures and techniques are reorganized under IATF 16949 also known as ISO/TS 16949
(Formerly known as ISO 9001)
APQP is very vast topic to explain today, to get an
idea I will show you an example

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Scope of mechanical design engineer:
APQP

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Scope of mechanical design engineer:
Designing conceptPlanning Designing 3D
Designing 2D Design for
manufacturing
Prototyping

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Product calculation
Testing
Documentation
Scope of mechanical design engineer:

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Assembly trial
and training
DFMEA
Final trial at customer end
Scope of mechanical design engineer:

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Scope of mechanical design engineer:
What were last 4 slides about?
Why was I watching them? What is the point?
The last 4 slides were the small glimpse of
what is expected from a design engineer, they
are part of skill required in a design engineer.
No employer pays you because you are
mechanical engineer after studying for 4
years, they pays you for the skills you posses
as mechanical engineer.
Engineering passing every year = 12,00,000
Mechanical or related field engineer passing
every year = 3,00,000
Students targeting core sector jobs every year
= 2,00,000
Total competition = current pass out batch +
50% seniors + 25% juniors
On an average 4,00,000 mechanical
engineers are applying for jobs> 2,00,000

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Scope of mechanical design engineer:
Competition is tough how can I get job?
How and from where I can learn them?

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After today’s session :
Introspection
Evaluate your position
Find your motivation
Make plan and follow it

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Well all of these facts are known since past 3 decades, then what is changing recently?
Every company follows these steps? What is new? Why should we change?
What is the challenge in coming decade?
What is this now?

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Understanding Industry 4.0 :
Engineer 1.0 Engineer 2.0 Engineer 3.0 Engineer 4.0

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Understanding Industry 4.0 :
Fourth Industrial Revolution or Industry 4.0> was first mentioned by Bosch at the Hannover Trade
Fair in 2011. Experts at the trade fair said that a new Industrial Revolution had arrived with
innovations brought into production by the modern face of the information era. When the German
Government took these opinions seriously, the Fourth Industrial Revolution had become
official. After the trade fair, a working group on the Fourth Industrial Revolution was established.
One year later, this working group presented its suggestions for the actual implementation of
Industry 4.0 at the next Hannover Trade Fair, and reported this to the German Government. Bosch
executive Siegfried Dais and SAP AG executive Henning Kagermann co-chaired the working group.

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Understanding 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 (IoT) platforms
• Location detection technologies
• Advanced human-machine interfaces
• Authentication and fraud detection
• 3D printing
• Smart sensors
• Big analytics and advanced processes
• Multilevel customer interaction and customer profiling
• Augmented reality/ wearables
• Fog, Edge and on-demand availability of computer system resources
• Data visualization and triggered "live" training
Mainly these technologies can be summarized into four major
components, defining the term “Industry 4.0” or “smart factory”:
• Cyber-physical systems
• IoT
• On-demand availability of computer system resources
• Cognitive computing

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What you showed in last few slides, all was about Big data, IoT, Cyber world, electronics?
How was all of this relevant to us as mechanical engineer?
This must be topic for CS and IT students why we are here?
If there is a humble way to put it, Industry 4.0 will depend heavily on Mechanical Engineers
for its evolution, in its attempt to connect physical and digital, its adaptation into best practices
and in its endeavour towards efficiency and sustainability. I have seen how there is a general
confusion around their role in an industrial revolution powered heavily by digitization (and often
mistakenly attributed to be the domain of IT & Electronics alone). Despite the buzz around Big
Data, AI and IoT (Internet of Things), it is necessary to realize that Industry 4.0 in its truest
sense is a manufacturing revolution and by that very nature, its successful implementation
and evolution will hinge greatly on mechanical design engineers (their skills, adaptation to
digitization and innovative approach.)
In next few decades the Mechanical design engineer will not only design machine, but instead we
have to design intelligent machines and product which are capable to interact with the world
smartly with help of capturing crucial data points and developing algorithms.
Adaptation and Integration for Industry 4.0 :

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So what do you suggest? Mechanical design engineers now also need to learn cyber technology
and artificial intelligence etc? Sounds like never ending studies?
No, they key is adaptation and integration for current situation, purpose is to illustrate the
connection between IT, manufacturing, product life cycles (through a three-dimensional space).
This provides a means of reference when discussing I4.0 architecture, the design of automation
products and for engineering manufacturing systems.

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What this revolution will change for mechanical engineers in designing profession?
How should we prepare ourselves for its adaptation?
New technologies and manufacturing principles are being developed every day. It is critical that
partnerships are created between industry and educational institutions to benefit from their full
potential. How can Industry 4.0 factories be designed? How can legacy systems be connected?
How does the manufacturing worker operate equipment? How do we improve the engineering
process? Technology is only useful if it can be implemented, and implementation requires
education.
Systems can be designed with more versatility and purpose by connecting the product’s
development into an integrated process for automation engineering. Costs could be reduced
through object-oriented design and virtualization, the value life of manufacturing systems could be
increased, and the products themselves could be brought to market faster.
Adaptation and Integration for Industry 4.0 :

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Is it only limited to manufacturing and automotive products?
Adaptation and Integration for Industry 4.0 :

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Well this was the concern also in past 3 industrial revolution, and here we still exist. Although the
required skill set changes, the way we work changes, but it always changes to better.
Human labour is not eliminated in Industry 4.0, but redefined. People are needed to design systems and
automation products, develop software for control systems and communication, operate and maintain
new technologies, and create machine learning algorithms for manufacturing operations.
The automation of Industry 4.0 can exist today, and we can start piecing it together to move towards a
manufacturing economy that can meet the demands of the modern world while remaining profitable and
productive.
Well seems in this case, we require very less workforce , this model maybe suitable for Europe or
America on a contrary Asian market is already over flooded by workforce & being worlds 2nd largest
population, is this revolution concept suitable for India?
Adaptation and Integration for Industry 4.0 :
This can be interpreted as choosing Mechanical engineering was a bad option, I should have gone with
robotics or mechatronics engineering, It too late now.
There is a big reason why mechanical engineering is sometimes referred as ‘Evergreen branch’. The
basic concepts of physics, thermodynamics and mechanics are never going to be changed even if it is
Industrial revolution 10, and robotics and mechatronics will always called Sub-branches of mechanical
engineering.
But we definitely need to redefine our skills, we need a lot more skills what we have now, I will show you
an example what will employer expect from Design engineer in future.

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https://www.linkedin.com/jobs/view/1889779287
This is original job posting on linkedIn which demonstrates what is expected by design
engineer in near future so we can plan and prepare ourselves:
Adaptation and Integration for Industry 4.0 :

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