Emerging manufacturing systems will be smart, sustainability and responsive to customer needs. Industry 4.0 offers an interesting platform. It is an integrative and all embracing architecture.

1. Emerging Manufacturing
systems
S G Deshmukh
ABV-Indian Institute of Information Technology &
Management , Gwalior
National Conference on “ Emerging Trends in Manufacturing & Automation
Engineering (NCMAE-2018)”
Amity University Madhya Pradesh, Gwalior
12 Oct 2018
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2. Acknowledgement
 Insights gained from Prof Jay Lee’s
session (on 28th
Sep 2018) IIIE
convention in Bhubneshwar
 Discussions with Prof R P Mohanty,
Prof Manoj Tiwari, Dr Kota
Harinarayana, Mr Ashutosh
Chincholikar and Mr Baba Kalyani
have helped in crystallizing ideas
presented here.
 Disclaimer : Various sources are mentioned wherever possible. In case
there are omissions, , these are not deliberate . Same is to be excused
for inadvertent omission !
2

3. Background material
from..
 Session as Chief Guest, National Seminar on
Emerging Trends in Manufacturing Automation
Engineering(NSMAE-2015), Amity University,
Gwalior , 9th
Oct 2015
 “Industry 4.0 and Make-in-India “
:https://www.linkedin.com/pulse/industry-40-
implications-technical-institutes-sanjeev-
deshmukh?trk=pulse_spock-articles
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4. Key talking points ..
 Opening remarks- Today’s manufacturing
– need /imperative
 Interesting developments
Connected world
Device vis-à-vis human being
Service oriented manufacturing
Industry 4.0
 Insights
 Closing remarks

5. Opening quote..
“Disruptive technologies such as 3D Printing, Cloud
Computing, Smart Sensors 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 employment generation by democratising
manufacturing using smart technologies in an environmentally
sustainable manner to leapfrog to the future.”
Prof. Sir Mike Gregory, Cambridge Univ., UK &‐
Dr. Baldev Raj, NIAS, Bangalore

6. http://www.mckinsey.com/business-functions/operations/our-insights/the-
future-of-manufacturing
Future of manufacturing..
McKinsey report (2012) & Roundtable meeting at Bangalore (21-22 Oct
2016)

7. Global Competitiveness (2016) & Industry
Perspective (2014) .. By Deloitte.
Global Manufacturing
Competitiveness Study
https://www2.deloitte.com/us/en/pages/manufacturing/
articles/global-manufacturing-competitiveness-
index.html
Industry 4.0
http://www2.deloitte.com/content/dam/Deloitte/ch/Documents
/manufacturing/ch-en-manufacturing-industry-4-0-241

8. Observations..
 Today’s customer- Hyper-demanding & “Selfie” customer !!
 Customers are increasingly looking not just for spec
sheets and catalogues online but solution and problem
solving recipes
 Today's world : Hyper-connected
 Today’s manufacturing- Hyper- Smart and Sustainable
 Today’s buzz word –
 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

9. Insights ..1..
 Manufacturing – wealth generator
 Across the globe, governments, industrial
corporations have recognized the significance of
creating their own added value through production.
 One cannot compete globally unless manufacturing
is strong !
 To live well, a nation must produce well !!
 Manufacturing “systems” !

10. Manufacturing..
 Manufacturing matters. China, India &
Indonesia are in the top 15 manufacturing
nations by their share to world GDP.
 Manufacturing is not monolithic-it is multi-
lithic strategic function !
 Distinction between manufacturing &
services has blurred.
 It offers insights into new opportunities, agilities,
and capabilities !!

11. Various connotations..
 Flexible manufacturing systems
 Computer integrated manufacturing systems
 Intelligent manufacturing systems
 Smart manufacturing systems
 Sustainable manufacturing systems
 Reconfigurable manufacturing systems
 Lean systems/Six-sigma/agile systems
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12. Global Manufacturing
Competitiveness Index
 It is interesting to note that CEO’s 2016 survey
conducted by Deloitte on Global Manufacturing
Competitiveness puts India at 11th
position
 Happy news: India is positioned at 5th
position (next to
Japan) by 2020.
source : https://www2.deloitte.com/us/en/pages/manufacturing/articles/global-
manufacturing-competitiveness-index.html) .

14. Competitiveness factors

15. Key drivers..
The following are the key drivers contributing
to the global manufacturing competitiveness:
1. Talent
2. Cost competitiveness
3. Workforce productivity
4. Supplier network

16. Ubiquitous Information
Availability
Global markets are demanding more flexibility and
productivity
• Pressure of sustainability - 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 for smart
customers !
Information in any form, any time, any device

17. Insights ....
 “Information that drives the next century’s
structural strategic 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

18. Industry 4.0
Synergistic combination of industry and the
current Internet of Things (IoT) technology is
Industry 4.0
Initiated by Siemen’s view !
-An initiative for Smart Manufacturing !

19. Disruptive technologies behind
Industry 4.0
 Analytics and Big Data
 Mobile technology
 AI & Robotics
 Cloud Computing
 Social networking
 Manufacturing NOT in isolation but as an
integrative platform !!

20. Four big forces..
 Digitalisation of records, citizen’s information, effective
quality control at multiple and remote locations
 Personalisation of services tailored for individual
users and
user friendly enhanced services‐
 Localisation of services, point of contact, and
material use for quick
response, and environmental sustainability
 Democratisation
of service chain
through enhanced participation from service providers
and industry partners

21. The traditional
Factory
 Monolithic
 Hard wired
 Centralized
 Fixed locations
 Low skill set for labor

22. 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

23. 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

24. Insights ....
 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 ?
24

25. Implications ..1..
Various connotations
 Smart materials
 Smart controls
 Smart manufacturing processes
 Environment friendly operations
 Closer to customer and pulled by smart customer trigger

26. 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
 The manufacturing will be Smart, Social ,Scalable ,
Sustainable & Synergistic !
 Benefits : Reduction in manufacturing cycle time and at the
same time, the vision is to have mass customization
affordable with intimate knowledge about customer!!

27. Observations ..1..
 Everywhere, digital transformation is making disruptions
 Traditional ways of conducting research and disseminating
outcomes have also changed
 The way we communicate and disseminate has changed.
 Contemporary research in Manufacturing Systems (MS) is
no exception to this !
 Collapsing of discipline boundaries
 Developments in IT have made integration possible
 Focus on emerging collaborative environment
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28. Observation..
 Cyber-Physical systems
 People have become smarter via
machines
 Data as an asset
 AI as cognitive science
 Industrial AI?
 Source: Source: Dr. Jay Lee/ Ohio Eminent Scholar and Univ. Distinguished
Professor at the Univ. of Cincinnati /founding director of National Science Foundation
(NSF) Industry/University Cooperative Research Center (I/UCRC) on Intelligent
Maintenance Systems (www.imscenter.net)
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29. Issues
Traditional
Manufacturing
 Man
 Machine
 Method
 Material
 Measurement
 Maintenance
Smart
Manufacturing
 Connect
 Cloud
 Cyber
 Content/context
 Community
 Customisation
29
Source: Dr. Jay Lee/ Ohio Eminent Scholar and Univ. Distinguished Professor at the Univ. of Cincinnati /founding
director of National Science Foundation (NSF) Industry/University Cooperative Research Center (I/UCRC) on
Intelligent Maintenance Systems (www.imscenter.net)

30. Observation..
 Huge data
 We require “knowledge” and insights
 Making meaning out of huge data ?
 Human intelligence & Creativity
 Human centred systems ?
30

31. Implications:
Curriculum on Smart
Manufacturing
 B Tech Programme in Smart Manufacturing
at IIITDM Kancheepuram !
http://www.iiitdm.ac.in/img/curriculum/B.Tech/MSM_C
urriculum_16-05-2017.pdf
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32. Implications: Hakumi !!
 Hands on ..
 Teaching Learning Centre for Design &
Manufacturing Education & National
Resource Centre for Design &
Manufacturing Education at IIITDM K
Visit : tlc@iiitdm.ac.in
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33. Observation..
 Manufacturing- No more only MECH Engg!
 It is now an amalgamation and collaboration of
various disciplines
 An interdisciplinary approach should be adopted
drawing on the expertise of a team comprising
manufacturing engineers, IT experts, psychologists,
ergonomists, social and occupational scientists,
doctors and designers.

34. Industry 4.0 - basic tenets …
 Interoperability: the ability of cyber-physical systems (i.e. work piece
carriers, assembly stations and products), humans and Smart Factories to
connect and communicate with each other via the Internet of Things and
the Internet of Services
 Virtualization: a virtual copy of the Smart Factory which is created by linking
sensor data (from monitoring physical processes) with virtual plant models
and simulation models
 Decentralization: the ability of cyber-physical systems within Smart
Factories to make decisions on their own
 Real-Time Capability: the capability to collect and analyze data and provide
the insights immediately
 Service Orientation: offering of services (of cyber-physical systems,
humans and Smart Factories) via the Internet of Services
 Modularity: flexible adaptation of Smart Factories for changing
requirements of individual modules

35. Interdisciplinary research-
Connotations from literature ..
Interdisciplinary research involves variants of the following
“integration” (Wagner et al., 2011),
“convergence” (Fuller, 2011),
“synthesis” (Rafols and Meyer (2010),
 “fusion” (Krohn, 2010),
“amalgamation” (Bozeman and Boardman, 2014) ,or
“unification” (Dupré, 2006).
Common among these definitions is an emphasis on the
ability to move beyond single disciplines to address research
topics from new perspectives, theories, concepts and
methodologies that together form a body of knowledge
beyond the traditional disciplinary boundaries.
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36. Interdisciplinary research:
NSF perspective
 “Interdisciplinary research is a mode of research by teams
or individuals that integrates information, data, techniques,
tools, perspectives, concepts, and/or theories from two or
more disciplines or bodies of specialized knowledge to
advance fundamental understanding or to solve problems
whose solutions are beyond the scope of a single discipline
or area of research practice.“*
*Committee on Facilitating Interdisciplinary Research, Committee on Science, Engineering, and Public
Policy (2004). Facilitating interdisciplinary research. National Academies. Washington: National
Academy Press, p. 2.
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37. Interdisciplinary research:
European perspective
 Horizon 2020 is the biggest EU Research and Innovation programme ever
with nearly €80 billion of funding available over 7 years (2014 to 2020) – in
addition to the private investment that this money will attract. It promises
more breakthroughs, discoveries and world-firsts by taking great ideas from
the lab to the market
 European Framework Programme for Research and Innovation “Horizon
2020” presents an instructive example of the deliberations in major
interdisciplinary programmes.
https://ec.europa.eu/programmes/horizon2020/
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38. Interdisciplinary research:
Experience sharing
 Doctoral work (Vedpal Arya ) on exploring
supply chain of medical devices /dental
implants
 Arya V, Deshmukh SG & Bhatnagar NB (2016),Value Creation in Dental
Implant Supply Chain, 10th
World congress for oral implantology & AAID
congress, New Delhi , 11-13 Nov 2016
 Arya, V, Deshmukh, SG., & Bhatnagar, NB (2015), High Technology Health
Care Supply Chains: Issues in Collaboration. Procedia-Social and Behavioral
Sciences, 189, 40-47
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39. Manufacturing systems:
Opportunities
 Looks at both hard and soft aspects
 Looks at both cyber and physical worlds
 Looks at both knowledge creation &
knowledge use
 Looks at both man and machine aspects
 Looks at both data and knowledge/insights
 Looks at Bigger Systems Perspective
39

40. Sustainable Development
Goals (SDGs)
40
Source: "Sustainable Development Goals(SDGs)” a linked in post by Muhammad
Akram
https://www.linkedin.com/pulse/sustainable-development-goalssdgs-muhammad-akram/

41. Issues to ponder..
 Loss of job opportunities due to Industry 4.0?
 Skilling, de-skilling requirements ?
 Scope of automation in India?
 Investment in infrastructure ?
 Huge consumption vis-à-vis sustainability ?
41

42. Context
 Manufacturing systems create material wealth for humans
 They consume a great amount of resources while generating a
lot of waste.
 The waste generated during the manufacturing processes,
during the use of the products and after the end of the life of the
products is responsible for the degradation of the environment.
 To minimize the resource consumption and the environmental
impact of manufacturing systems has become increasingly
more important.
 Do consumption and Sustainability go counter
to each other? 42

43. Elephant & Six blind men
…

44. Views of elephant
 Manufacturing view
 Networked view
 Cyber-Physical view
 Business view
 Sustainability view

45. Industry 4.0.
 Industry 4.0 means different things to different
people – smart factory, pull based factory,
networked factory, cyber-physical integration etc.
 Industrie 4.0 goes by a variety of names:
‘Advanced Manufacturing’ in the USA/UK,
 ‘les usines du futur’ (The Factories of the Future) in
France,
 ‘Made Different – Factories of the Future’ in Belgium,
and
 “Smart Industries” in the Netherlands.

46. Closing remarks ..
 Industry 4.0 offers a useful platform for
manufacturing as an integrated system of cyber
and physical worlds !
 Creative role of human beings amidst big data!
 Systems perspective !!
46

47. Top 10 Skills to be relevant in
Industry 4.0

48. 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.

49. Enablers of smart factory in Gwalior
…
 Smart Controls India Ltd : A company started
by MITS alumnus, Ashutosh Chincholikar
 http://www.smartcontrols.in/
Joint Venture between "Smart Controls India
Limited & Zeppelin Systems GmbH",
Zeppelin Systems GmbH is a 2.7 b€ group
headquartered in Germany and present in
almost every corner of the world.
https://www.zeppelin-systems.com 49

50. Thank you
deshmukh.sg@gmail.com