In the era of globalization, industrial organizations are under continuous pressure to innovate, improve their competitiveness and perform better than their competitors in the global market. And with that in mind, in this article we will clarify what is Industry 4.0 and how it can apply to your shop.
What is Industry 4.0?
The term Industry 4.0 marked the “official” start of the fourth industrial revolution, which is based on the use of in industrial plants as a means of fostering the digitization, automation and intelligence of industrial processes.
This revolution is driven by the interconnectedness of advanced technology, automation, robotics, artificial intelligence (AI) and real-time data. It is also commonly referred to as the Internet of Things (IoT). While these cyber-physical systems can independently trade information to trigger actions and make decentralized decisions, it’s impossible to dismiss the importance of the human element in manufacturing.
Industry 4.0 Principles and Goals
- Artificial Intelligence (AI): The ability of machines or software systems to simulate human mental prowess.
- Interconnection: The ability of machines, devices, sensors, and people to connect and communicate with each other via the .
- Information transparency: The ability of Industry 4.0 technology to provide a level of transparency that gives operators access to vast amounts of useful information and inform appropriate decisions. Additionally, the ability to collect immense amounts of data and information from all points in the manufacturing process to aid functionality and identify key areas that can benefit from improvement and innovation.
- Technical assistance:
- Decentralized decisions:
Shop Floor Integration
The picture below shows the typical value stream of a Machine Shop. But with the fourth industrial revolution, there is now a digital thread connecting the value stream.
Guaranteeing the quality and reliability of processes and products, may include the following elements:
- Tool Monitoring: With modern techniques including embedded sensors, tool monitoring can be done to improve machine up-time, part quality, optimization of tool life, and can help maximize overall machining efficiencies.
- Predictive maintenance: Monitoring machines during uptime and providing critical data to indicate possible issues or upcoming repairs that need to be made. This way the shop can plan for required maintenance and avoid unnecessary downtime, reducing maintenance costs and increasing the availability of the machine.
- Machine sensors and transmitters: Sensors and transmitters allow machines to monitor internal processes and detect problems, even before they arise. Also, the data collected by smart sensors offer numerous opportunities to not only reduce downtime but to improve productivity and product quality. These smart sensors can also be programmed to detect smoke, noise, VOCs, and other conditions to reinforce safety efforts.
- Remote monitoring and signals: Remote sensors guarantee employees have the right tools and materials at the right time to operate most efficiently. For example, these devices are being used to detect when materials or parts need to be restocked, therefore supporting an efficient parts flow.
- Real-time quality and safety data: Access to real-time quality and safety metrics allows employees to do their jobs more efficiently and address issues before they become real problems that could impact product quality or on-time delivery to customers. Monitors with dynamic dashboards tracking key performance indicators can be installed throughout plants, providing all employees with immediate access to data, which makes it possible for them to see performance against productivity targets, quality metrics, and safety information.
Triumph Tool proudly represents several supplier partners that offer solutions to create a connected machine shop.
Sandvik Coromant, for example, has the CoroPlus™, a connected platform which offers design and planning solutions, as well as in-machine monitoring solutions. Prometec GmbH, a division of Sandvik Coromant, is a leading supplier of advanced solutions for monitoring and control of machining processes in production machines.
Haimer is one of our Supplier Partners that has embraced Industry 4.0 and are currently setting new standards for digital connectivity and communication between tools and machines. For example, this forward thinking is reflected in the i4.0 generation Power Clamp shrink fit machines (Premium i4.0, Sprint i4.0 and Comfort i4.0) and in the HAIMER DAC (Data Analyzer and Controller). This digital tool management system enables a consistent exchange of tool data and can connect an entire shop (including CAD/CAM and machine tools) with a digital Industry 4.0 system.
Supply Pro, a leading inventory management solutions provider, is leveraging the most advanced Big Data Analytics techniques to dramatically transform the industrial distribution and manufacturing industries. The SupplyPro platform combines the power and flexibility of the cloud with mobile solutions and the industry’s first modular, IoT-enabled smart inventory control system.
To learn more about these and other innovative solutions, please contact us.