Industrial Digitalization and Industry 4.0: Transforming Traditional Industries Through Data
Industries are
under immense pressure to perform better with less. They are faced with a
challenge of producing at a higher output, and if anything is idle, money goes
down the drain. On the other hand, a lot of industrial settings have been
carrying out checks by hand. This is done with a strict process, providing them
with little to no information on what is happening on the shop floor.
At this juncture,
the role of industrial digitalization assumes its importance.
Industrial
digitalization involves basically the use of
digital technology to interpret and respond to the information obtained from
machines and processes. Industry 4.0 basically involves the integration of
automation, connectivity, and decision-making using data with digitalization.
Notwithstanding the
highly technical nature of Industry 4.0, it is not an industry with complex
technologies to deploy and utilize. This is because the essence of Industry 4.0
is found in its efforts to improve functionality and make the industry more
efficient and capable of meeting the challenges found in the constantly
changing world of the industry.
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Industry Digitalization: What It Truly Means
Industrial
digitalization is, basically, the process by which physical activity is turned
into useful data.
Every machine
running on the shop floor generates information for temperature, pressure,
speed, vibration, cycle time, and energy usage. Traditionally, many of these
points of information were overlooked or examined on an inspection basis. This
tendency will continue and these points of information will then be evaluated
when a machine goes faulty or impacts quality.
This type of
information has been easily collected by sensors and network technology through
the process of digitalization. It helps the following industries:
•Clearly understand
the performance of machines
•Identify the point
of wear or component failure
•Improve production
planning
•Reduce unplanned
breakdowns
•Optimize Energy
and Resource Utilization
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What are the components of Industry 4.0
Industry 4.0 deals
with integrating machineries, processes, and people through data.
In the digital
factory, machines were no longer operating in isolation. Rather, machines were
communicating with monitoring systems and dashboards and even other machines.
This meant that the following possibilities were created for the company:
•Manage multiple
machines remotely by displaying them all on one screen
•Display real-time
production output tracking
Forecasts related
to preventive maintenance based on anticipated occurrences
• Minimize material
wastage and use of energy
All these are
accomplished through a combination of sensors, software, and automation that
work hand-in-hand behind the scenes.
It is worth noting
that Industry 4.0 does not require the substitution of existing machines in the
industry. This is because the industry upgrades the existing systems via the
development of intelligence on the existing systems.
Industries are
becoming more and more complicated, and the margins are being squeezed.
Downtime, inefficiency, and lack of visibility are very quickly becoming costly
issues.
Digitalization
helps industries in the following ways:
•They need to make
their decisions on facts and not on hypotheses
• Function
effectively when a user is not constantly present.
•Improved safety by
identifying unusual events early
By utilizing an
automated system, it is able to Extend the life cycle of a machine through
efficient maintenance methods
In fact, a small
amount of optimization, such as decreasing the amount of idle time, can make a
world of difference.
Role
of Industry 4.0 Solutions Provider
Industry 4.0 is
much more than a system installation or a software process, because it entails
industry insight, resulting in successful implementation.
An Industry
4.0 solutions provider assists industries by:
•Knowledge of
Operational Pain Points & Constraints
•Providing relevant
digital solutions to meet real-world conditions
•Integrating
Hardware, Software, and Existing Systems
•Ensuring smooth
and trouble-free implementation
•After acquiring
the product or service, one aspect which
There’s not much
stress on the use of technology but rather the value-addition done by the
technologies for efficiency, dependability, and traceability.
Technologies
Used in Industry 4.0
Although these are
easy to understand, many crucial technologies are used:
Industrial
Internet of Things
They are capable of
acquiring real-time data from machines and processes.
Industrial
Automation Systems
There is smoother
functionality and minimal human interaction.
Data Visualization
Dashboards help
convert data into more meaningful and actionable information.
Predictive
maintenance
They have planned
their maintenance before the occurrence of a failure.
Secure
Connectivity
Data is shared
between computers, systems, and platforms with security.
They also could be
modular, which helps the industry accept them module by module.
Is Industry 4.0 Exclusive to Large Scale
Industries?
No.
"Industrial digitalization does not have to be large or complex,"
according to Richard Susskind.
Organizations take
up small targeted actions like:
•Tracking only one
key machine
•Monitoring the use
of energy in the specific area of the plant
•Digitization of
maintenance and inspection records
Sectors
That Benefit from Industry 4.0
Industry 4.0
solutions have already been implemented in many industry sectors, including:
•Manufacturing
•Energy & Power
•Mining
•Steel and metals
•Car manufacturers
•Logistics and
storage
•Process industries
Every area of the
business that has machines, equipment, and/or complex business processes can
benefit from digitalization.
Overcoming
Common Digitalization Challenges
Generally,
industries are skeptical concerning digitalization, especially with respect to
cost complexity and integration with already installed machinery.
These drawbacks
could be eliminated by:
•Modular and Phased
Implementation
•With a Scalable
Systems that Grow Over Time
•Scalable systems
Application of non-intrusive sensors and gateways
•Little Impact on
the Existing Processes
•Training and
technical support services
Digitalization done
the right way also creates the impression of evolution and not revolution.
Conclusion
With the presence of industrial digitalization not anymore on the
agenda but already a real and viable option for achieving greater efficiency,
reliability, and sustainability for the sustainable development of the future,
the time to plan out an efficient strategy for industry 4.0 and execute this
strategy with the help of the right partners and solution givers is now.
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