2. Industry 4.0
Industry 4.0 is the digital transformation of
manufacturing;
leverages technologies, such as Big Data and
Internet of Things;
requires the convergence of IT (Information
Technology) and OT (Operational Technology);
realizes connected factories, smart
manufacturing, self-optimizing systems and digital
supply chain in the cyber-physical environment.
3. The fourth Industrial Revolution
Pervasive use of:
✔ data and information;
✔ computational technologies and data
analysis;
✔ new materials;
✔ machines, components and automated
systems digitized and connected.
4. The fourth Industrial Revolution
Takes the automation of manufacturing processes
to a new level by introducing customized and
flexible mass production technologies.
Allowes machines to operate independently, or
cooperate with humans in creating a customer-
oriented production field that constantly works on
maintaining itself.
Introduces self-optimization, self-cognition, and
self-customization into the industry.
5. KET in Industry 4.0
(key enabling technology)
● BIG data
● Internet of things (IoT)
● Augmented reality
● Simulation
● Advanced robotics
● High connectivity
● Additive manufacturing
6. BIG data
Large and complex set of data that requires the
definition of new tools and methodologies to
extrapolate, manage and process information
within a reasonable time.
Big Data parameters:
✔ Volume
✔ Speed
✔ Variety
7. Internet of things
(IoT)
IoT is a neologism referred to the extension of
the Internet to the world of objects and concrete
places.
Through the chips and sensors inserted inside
them, the objects are able to interact with each
other and with the surrounding reality.
The physical world can be entirely (almost)
digitized, monitored and in many cases
virtualized.
8. Augmented reality
Technology, associated with computer graphics,
which thanks to electronic devices is able to
increase the sensory perception of man.
It differs from virtual reality due to the fact that
experience takes place in a combination of
physical environment and virtuality and not
only in immateriality.
The AR allows access and use of additional
information, directly in their contexts of use,
overlapping levels of digital information to the
physical space and allowing to interact with them.
9. Additive manufacturing
The set of production processes that starts from
digital models, in contrast with traditional
subtractive techniques (machining by removing,
cutting and drilling chips).
It starts from a 3D CAD model that is divided into
layers by a software integrated into the machine
control system, or by online services; the pattern
of resulting layers guides the printer into
deposition, or sintering, of the material.
10. 4IR – Technologies application
The new technologies are already widely available
and present in companies, but at present their
application is still limited and sporadic, being
mainly concentrated on the control of industrial
process for the mass production of components
(CNC machines), integrated with robotics only in
certain environments, with applications limited
to the repetition of the same action or task and
to the remote control of the operational efficiency
of the machinery.
11. 4IR – Technologies networks
With the transformation in key 4.0 it
is instead possible to manage real
networks that incorporate, integrate
and put into communication
machinery, plants and production
facilities, logistics and warehousing
systems, distribution channels.
12. 4IR – Digital trasformation
Through digital transformation - and with
the use of cyber-physical production
systems - the production sites are able to
react more quickly, almost in real time, to
changes in demand, product specifications,
supply flows of raw materials optimizing
transformation processes, reducing errors
and defects, improving time to market and
ensuring flexibility, speed and precision.
13. 4IR - Integration
The field of Industry 4.0 goes beyond the single
enterprise as it goes beyond the single machine.
Innovation 4.0 is not about introducing state-of-
the-art machinery from a technological point of
view, but in knowing how to combine different
technologies and in this way integrate the factory
system and the production chains so as to make it
an integrated, connected system in which
machines, people and information systems work
together to create smarter products, smarter
services and smarter work environments.
14. 4IR - Customization
The role of the consumer-user changes:
the analysis of individual needs acquires
increasing importance, as well as the ability
to satisfy the demand through the mass
customization of the products. It becomes
possible to vary the production mode in line
with the variations in demand or type of
product, in a logic of modularity and
continuous re-configurability.
15. 4IR - Benefits
There are significant impacts in terms of
sustainability, in particular with regard to
aspects related to workplace safety, to the
optimization of consumption of energy and
non-energy resources, to production models
of a circular nature to reduce waste, scrap
and waste (production with zero defect) and
to favor the recycling/reuse of materials and
secondary raw materials.
16. 4IR - Digitalization
Digitization is a phenomenon that gives a
further boost to the transformation
processes, accelerating their evolutionary
changes along some distinctive lines:
- interconnection - virtualization
Cyber-physical model
- decentralization - remote interaction
- real time processing and reactions.
17. 4IR - Interconnection
Ability of the asset to exchange information
with internal systems (management system,
planning systems, product design and
development systems) and/or external
(customers, suppliers, partners in designing
and collaborative development, other sites
of production, supply chain) by means of a
link based on documented specifications,
publicly available and internationally
recognized.
18. 4IR - Virtualization
A "virtual copy" (digital twin) of the
real system and/or its components
is created and updated through data
coming from appropriate sensors
and for which it is possible to
predict the evolution of behavior
through simulations.
19. 4IR – Cyber-physical model
The combination of physical components
(systems, machines) and digital twin gives
rise to the so-called cyber-physical model,
which sketches production models in which
the time and costs of the transition from the
prototyping to the production phase are
reduced, and where the production process
is able to be simulated in every function and
moment.
20. 4IR - Decentralization
The various cyber-physical
components, that make up the
production plant, have appropriate
strategies to correct process drifts
independently, and to review their
behavior in the presence of
anomalies.
21. 4IR - Remote interaction
The devices are remotely accessible
so as to be able to detect data on
the operation or introduce
corrective measures.
Typical examples of enabled
functions are those of remote
monitoring and maintenance.
22. 4IR - Real time processing
Functions that allow to collect in real
time (with sampling fast enough to
follow the dynamic characteristics of
the related processes) the process
data and to undertake the relative
actions / elaborations.
23. 4IR - Adavantages
The adoption of digital technologies, typical
of the fourth industrial revolution, allows
value chains to obtain a series of
advantages, that guarantee an increase in
productivity and competitiveness of
companies.
Some of the most evident advantages, of the
fourth industrial revolution, can be
summarized in an improvement of:
24. 4IR - Adavantages
● Flexibility through the production of small lots
to the costs of the large scale with important
consequences in terms of customization;
● Speed from prototyping to mass production
through innovative technologies that reduce
set-up times and accelerate go-to-market times;
● Productivity through greater operational
flexibility and system reconfiguration, resulting
in reduced costs and waste, increased reliability
of production systems and yield quality
(reduction of errors, defects and downtime);
25. 4IR - Adavantages
● Integration of supply chains and
subcontracting through improvements
in procurement and logistics systems,
more efficient inventory and order
management, optimization of
relationships with suppliers, even in a
key of less conflict in open and
collaborative ecosystems;
26. 4IR - Adavantages
● Sustainability through a reduction in
energy consumption and use of raw
materials, emissions, with a consequent
reduction of the environmental impact
over the entire life cycle of the product;
● Product innovation thanks to new digital
technologies that make it possible to
revisit many products in a smart key and
review service models and market
approaches.
27. 4IR - Adavantages
● Safety through a better interaction and agility of
man-machine interface, that makes possible a
significant reduction of errors and injuries, and
an improvement in the safety and ergonomics
of the workplace. Production systems, that
support and assist the operators in carrying out
their duties, lead to a reduction in work-
related stress and to the overcoming of some
limits in terms of the availability of personnel
already trained, the aging of the workforce, the
integration of workers with disability.
28. SAFETY & HEALTH
Safety
a state in which or a place where, you are
safe and not in danger or at risk.
Health
state of complete physical, mental and
social well-being, not only consisting in the
absence of sickness or illness – (WHO).
29. INAIL & Industry 4.0
Inail rewards companies, with a "discount" called
"oscillation for prevention" (OT/24), if they perform
actions beyond the minimum required by
Legislative Decree n°81/08 for the improvement of
the conditions of safety and health in the
workplace.
Safety and security of workers, as well as being a
legal and social obligation, is an advantage from
an economic point of view: it allows to prevent
illnesses and accidents at work and is also an
important component of a company's success.
30. INAIL & Industry 4.0
Devices that can improve conditions of safety and
health in the workplace:
✔ devices for human-machine interaction and for
the improvement of ergonomics and workplace
safety in the «4.0» logic.
✔ desks and workstations equipped with
ergonomic solutions able to adapt them in an
automated way to the physical characteristics of
the operators (for example, biometric features,
age, presence of disability).
31. INAIL & Industry 4.0
Devices that can improve conditions of safety and
health in the workplace:
✔ systems for lifting/translating heavy parts or
objects exposed to high temperatures able to
facilitate the task of the operator in an
intelligent/robotic/interactive manner;
✔ intelligent human-machine interfaces (HMI) that
support the operator in terms of safety and
efficiency of machining, maintenance and
logistics operations.
32. INAIL & Industry 4.0
Devices that can improve conditions of safety and
health in the workplace:
✔ wearable devices, communication equipment
between operators and the production system,
augmented reality devices and virtual reality.
✔ An example is made up of smart devices able
to provide instructions on the job and to view in
real time the data on the operation of the
machines and on the activities that the
operators will have to perform.
33. Industry 4.0 plan - MISE
Two priority objectives identified by
the Industry 4.0 Plan of the Ministry for
Economic Development (MISE):
1) the modernization of the
"instrumental goods park";
2) the technological and digital
transformation of Italian
manufacturing companies;
34. Industry 4.0 plan - MISE
Assets that benefit of hyper-depreciation:
1)Instrumental goods whose operation is
controlled by computerized systems or
managed by appropriate sensors and drives;
2)Systems for quality assurance and
sustainability;
3) Devices for human-machine interaction
and for improving the ergonomics and
safety of the workplace in logic «4.0».
35. Industry 4.0 plan - MISE
To benefit from the tax deduction of hyper-depreciation,
the assets must have the following characteristics:
1. Control by means of CNC and / or PLC;
2. interconnection with the factory information systems
with remote loading of instructions;
3. automated integration with the logistics system of the
factory, with the supply network, with other machines in
the production cycle;
4. simple and intuitive interface between man and
machine;
5. compliance with the most recent parameters of
safety, health and hygiene at work.
36. Industry 4.0 plan - MISE
Moreover the assets must be equipped with at least two
of the following additional features to make them
assimilable or integrable to cyber-physics systems:
a) remote maintenance and/or telediagnosis and/or
remote control systems;
b) continuous monitoring of working conditions and
process parameters by means of appropriate sensor sets
and adaptability to process drifts;
c) integration between the physical machine and/or the
plant with the modeling and/or the simulation of one's
behavior in the development of the process (cyber-
physics system).
37. Industry 4.0 plan - HMI
Devices for human machine interaction aimed at improving
ergonomics and devices for human machine interaction
aimed at improving workplace safety:
- Integrated ergonomic workstations in which the operator has
at his disposal intelligent transport modules, touch screen
terminals, anti-glare and customizable lighting of the
workstation, elements with articulated arm, electrically
adjustable work table in height;
- Intelligent devices able to provide instructions on the job and
to visualize in real time the data on the functioning of the
machines and on the activities that the operators will have to
perform.
39. SAFETY Tools - 3.0
● Helmet;
● protective headphones;
● glasses;
● protective mask;
● work overalls;
● working gloves;
● work shoes.
40. SAFETY Tools 4.0 - a)
How could you image 4.0 safety tools?
✔ make a list of safety tools;
✔ define, for each one, sensors that can be
integrated.
41. SAFETY Tools 4.0 - b)
Which data could be detected by advanced and
integrated SAFETY Tools?
Classify the type of parameters referring to:
✔ surrounding environment;
✔ physiological conditions of workers;
✔ machine parameters.
42. SAFETY Tools 4.0 - c)
Could you define the flow of data?
✔ sensors detect parameters and send data to . . .
✔ data are processed by . . .
✔ processed data are returned to . . .
✔ data are recorded by . . .
✔ which data are recorded in the short and long
term?
43. SAFETY Tools 4.0 - d)
How 4.0 safety tools could increase the sensory
perception of man?
Give some examples . . .
What advantages derive from it?
