Industry 4.0, the 4th Industrial revolution, is redefining manufacturing in 2020. Smart Factory, Smart Manufacturing, Digital Manufacturing, Artificial Intelligence, Big Data etc. are commonly herd terms nowadays. But what exactly do they mean? What is Industry 4.0? What were Industry 1.0, 2.0 and 3.0? How does Industry 4.0 positively impact the way a Factory manufactures? What are the benefits of Industry 4.0? How can a factory become a Smart Factory? How to get started with Industry 4.0 journey? How to achieve manufacturing excellence using Industry 4.0 route? What is Digital Manufacturing and Smart Manufacturing? These and some of these questions are answered in this updated (July 2020) Industry 4.0 IIoT Webinar Presentation (PPT, PDF).

1. Industry 4.0 IIoT Webinar
ENERCO Energy Solutions LLP

2. Agenda
• About ENERCO Energy Solutions LLP
• Present Scenario
• What is Industry 4.0?
• Digital Manufacturing Aspects
• Why Industry 4.0?
• How to get started on Industry 4.0 Journey?
• Case-Studies

3. About ENERCO Energy
Solutions LLP

4. About ENERCO Energy Solutions LLP

5. About ENERCO Energy Solutions LLP

6. Present Scenario

7. Present Scenario
• Protectionism – Countries keen to protect their economy
• Rising Labor Costs in China
• Covid 19 disruption in Supply Chain
• Rising Patriotism (Making US Great Again, Buy Local in India etc.)
•BIG DATA AUTOMATION

8. Present Scenario
Source : Enser

9. Present Scenario
• Cost + Quality is a winning combination in the global arena
• Reshoring supported by AI / ML can reduce cost + proximity to the customer +
resilience + National Pride
• Manufacturers (especially in India) will have to adopt advanced technologies -
NOW !!!

10. What is Industry 4.0?

11. What is Industry 4.0?

12. What is Industry 4.0?
• Transformation using NEW age digital technology a.k.a. DIGITAL Transformation
• Is applicable to a variety of Industries including Manufacturing, Healthcare,
Retail, Telecom etc.
• In manufacturing it is primarily about gathering + analysis of data across
machines + Business Systems + remote plant operations & management
• Results in
• FASTER
• FLEXIBLE
• RELIABLE
• EFFICIENT PROCESSES
AT REDUCED COST !!!!

13. What is Industry 4.0?
• In the manufacturing context Industry 4.0 is all about Digital Manufacturing (in a
Smart Connected Factory) achieved by –
A. Data Collection
• Sensors
• Gateways
• Routers
• Media Converters etc.
B. Data Analysis
• Platform
• Artificial Intelligence & Machine Learning (AI/ML)
• Cloud

14. What is Industry 4.0?
C. Data Presentation & Storage
• Cloud
• Condition Monitoring, OEE , Energy Consumption
• Visualization (Trends, Real time data, Predictive modeling)
• Global Access (Web / Computer / Mobile App)
D. Control
• Actuators for control
• Process Improvement
• Remote Operations (for plant to operate even during lockdowns)
• Remote Asset Management

15. What is Industry 4.0?
Key terms to know
• IIoT: Industrial Internet of Things – a network of connected things constantly generating insightful data
• Big Data : Enormous data generated by all types of devices and equipment characterized by 3 Vs –
Variety, Velocity & Volume
• Artificial Intelligence : Intelligence demonstrated by machines and devices in contrast to
natural intelligence displayed by humans and animals
• Machine learning : Learning carried out by machines through study of trends and patterns
over a period of time to draw useful inferences
• Digital / Smart Manufacturing : Manufacturing activities in a digital landscape where
decision-making is purely data-driven with lesser human intervention

16. What is Industry 4.0?

17. Digital Manufacturing
Aspects

18. Digital Manufacturing Aspects

19. Digital Manufacturing Aspects
• Digital Twinning
• Virtual representation of a real-world object
• It helps in
• Remote Asset Management : representation of a machine /
equipment on shop-floor
• Product Development : design on the fly and integrate
• In simple terms asset management can be carried out once
all your assets can be seen on a screen (HMI)

20. Digital Manufacturing Aspects
• Benefits of Digital Manufacturing
• Cost saving
• Predictive Maintenance for breakdown avoidance (Prescriptive Maintenance – The ultimate goal !)
• Energy optimization through monitoring and control
• Improve Equipment life (RUL)
• Enhanced Productivity
• Improved OEEE
• Employee focus on more creative work while machines focus on mundane tasks
• Rapid customizations in mass production (part of Industry 5.0)
• Reduced go-to-market time

21. Digital Manufacturing Aspects
• Benefits of Digital Manufacturing
• Happier Customers
• Enhanced QA
• Goods traceability
• Programming of quality parameters
• Business
• Product innovation
• Business Cycle Predictability (Can we predict the new business downturn?!?)
• Sourcing & Procurement
• Business Continuity
AND MANY MORE BENEFITS…..

22. Why Industry 4.0?

23. Why Industry 4.0?
• Off-shore manufacturing model is challenged
• Cost-benefit of offshore manufacturing is narrowing
• Uncertainties in Global Trade (Tariff War)
• Western Companies are already in the midst of Industry 4.0
and in fact talking about Industry 5.0

24. Why Industry 4.0?
• Industry 4.0 touches upon all areas
Production
Maintenance
Supply Chain
Business Processes
Human Resources
Sales & Marketing

25. Why Industry 4.0?
• Higher reliance on Machines
• Industry 4.0 compliant factories can work even during
lockdowns
• Mundane & repetitive tasks done by machines efficiently
and at lesser costs eg. RPA (Robotic Process Automation),
Chat Bots etc.
• Rising labor costs

26. Why Industry 4.0?
• Cost + Quality Combination
• Rise of Quality-conscious customers in developing Nations
• Cost competitiveness through higher machine availability +
productivity

27. How to Get Started on
Industry 4.0 Journey?

28. How to get started on Industry 4.0
Journey?
Key considerations
 Necessary + unavoidable transformation  All Organizations
including your Competitors, your Clients, your vendors are going digital
 Clear business benefits  KPIs & KRAs defined
 Kaizen Project  Continuous Improvement in all areas that are being addressed in
the Journey
 Agile Methodology  Phase-wise implementation which takes place over a
period of time not a plug-n-play or a boxed solution
 All on-board  All departments to be a part right from the beginning

29. How to get started on Industry 4.0
Journey?
Timelines are indicative and for a small-sized unit

30. How to get started on Industry 4.0
Journey?
IIoT Audit consists of
 Technical Part
 Checking system readiness
 System Architecture
 Technical Requirements Gathering (Technical Processes, Challenges)
 Identification of Technologies – Hardware, Software, Protocols etc.
 Non-Technical Part
 Setting up Organization team
 Business Requirements Gathering
 Translation of Business Requirements to Technical Requirements
 Roadmap preparation on the way forward and next steps

31. Case-Studies

32. Case-Study : Steel Plant
1500°C
1500°C
1500°C
20-25 mins
queue time
1400°C
(minimum required)

33. Case-Study : Steel Plant
Solution Proposed
 Real-time liquid temperature monitoring (from manual sample to automatic all)
 Ambient temperature monitoring (new)
 Intelligent system to reduce queue time with closed-loop feedback system (new)
Benefits
 Queue time reduced from 20 mins to 10 mins
 Major coal-savings with financial payback of 4 months
 Enormous resource saving for the Nation

34. Case-Study : Utilities

35. Case-Study : Utilities
Solution Proposed
 Real-time condition monitoring of Utilities such as
Pumps
Compressors
Fans & Blowers
 Parameters monitored
 Temperature
 Vibration
 Humidity
 Sound

36. Case-Study : Utilities
Benefits
 8% Energy Saving (combined on all covered equipment)
 Predictive Maintenance improved system life (modeling predicts 16%
improvement in RUL)
 Improved equipment availability
 Payback within 6 months based on energy-saving alone

37. Webinar : Key-Takeaways
 IIoT can be used to solve a range of plant issues and discover a variety of
opportunities to Optimize Processes and Increase Revenue + Profitability
 There is no limit to what IIoT can achieve for a standard Indian manufacturing
plants  many of which are still not Industry 3.0 compliant
Industry 4.0 Projects have direct and indirect benefits for overall long-term plant
health and Company’s sustainability
 With Covid-19 the offshore model is being re-visited and Indian Companies will
have no option but to go for Industry 4.0 (& eventually Industry 5.0)

38. Questions?
Thank you !
Rathin Vyas
(NASBA & PMI U.S.A. Certified IIoT & Big Data Analyst)
Enerco Energy Solutions LLP
+91 9022545622
www.econserve.in