The document discusses future manufacturing trends in light of Industry 4.0. It notes that ubiquitous information availability, enabled by technologies like IoT, sensors, and cloud computing, will optimize resource use and allow for real-time, automated production. Industry 4.0 represents the synergistic combination of manufacturing and internet technologies, bringing concepts like smart factories with intelligent, networked production units. Key implications include smart materials and controls, environmentally friendly operations, mass customization, and the need for educational institutes to develop strong industry linkages and digital manufacturing training to support these changes.

1. FUTURE MANUFACTURING :
IMPRESSIONS, INSIGHTS & IMPLICATIONS
S G DESHMUKH
ABV-INDIAN INSTITUTE OF INFORMATION TECHNOLOGY & MANAGEMENT,
GWALIOR
Natio al workshop o Ma ufa turi g “yste s
Under TEQIP
MITS, 23 Oct 2016

2. Key talking points ..
• Today’s a ufa turi g – need /imperative
• Impressions
• Connected world
• Device vis-à-vis human being
• Service oriented architecture
• Insights
• Various implications
• Manufacturing & control
• Maintenance
• Workforce

3. Opening quote..
Disruptive technologies such as 3D Printing, Cloud Computing, Smart Sens
ors and ICT enabled logistics, are bringing a paradigm shift –
from centralized mass production to distributed customized manufacturing,
closer to end users.
India now has an opportunity to achieve its aspiration of large‐scale employ
ment generation by democratising
manufacturing using smart technologies in an environmentally sustainable
manner to leapfrog to the future.
Prof. Sir Mike Gregory, ‐ Ca ridge Univ., UK &
Dr. Baldev Raj, NIAS, Bangalore

4. My presentation based on
Manufacturing the future: Mckinsey report
(2012)
• http://www.mckinsey.com/business-
functions/operations/our-insights/the-
future-of-manufacturing

5. Industry Perspective (2014) ..
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

6. Academic Perspective (2016)
Future of Manufacturing
Roundtable meeting at Bangalore
(21-22 Oct 2016)

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 cannot compete unless manufacturing is strong !
•Ma ufa turi g syste s !

9. Manufacturing..
• Manufacturing matters. China, India & Indonesia are in the top 15
manufacturing nations by their share to world GDP.
• Manufacturing is not monolithic.
• Distinction between manufacturing & services has blurred.
•It needs new insights into new opportunities,
agilities, and capabilities !!

10. Impression 1:
Ubiquitous Information Availability
• Global markets are demanding more flexibility and productivity
• Resour e o su ptio has to e i i ized.
• 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 for smart customers !
• Information in any form, any time, any device

11. Insights ..2..
• I for atio that drives the e t ce tur ’s structural
strategic shift i a ufacturi g.
• Making real-time information available:
• when it is needed,
• where it is needed
• and in the form it is needed throughout the Manufacturing
ecosystem

12. 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 !

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

14. Four forces ?
• Digitalisation
• Personalization
• Localization
• Democratization

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

16. Smart factory ..at the heart of
Industry 4.0
• Smart 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 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 Execution
• Real time Dynamic coordination of decision in heterogeneous environments without losing control of
state
• Applications that can share data and data that can share applications and devices

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..
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 !

21. Implications
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.

22. 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

23. 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

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

25. Thank you
deshmukh.sg@gmail.com