The fourth industrial revolution, which has been taking place since the start of the 21st century, is driving the largest structural change that has not seen in the last 250 years. This transformational power comes from combining advanced production and operations techniques with digital technologies to create connected enterprises. This uses data to drive intelligent actions in the physical world.
Interestingly, Industry 4.0 makes a factory smart by applying advanced information and communication systems and future-oriented technologies. According to the NASSCOM, investments in Industry 4.0 have increased by almost ten-fold in the previous decade globally and are predicted to reach $200 billion by 2025.
Lean manufacturing, which is widely regarded as a potential methodology, to improve productivity and decrease costs in manufacturing organisations, requires consistent and conscious efforts from the organisation. It also has to overcome several hindrances. Committing into Industry 4.0 makes a factory lean besides being smart.
What is lean manufacturing?
Krafcik coined the term ‘lean’ to describe Taiichi Ohno’s revolutionary production methods. Lean is a broad term that incorporates a variety of management concepts and approaches. Despite its roots in manufacturing, Lean may be applied to any process-driven environment, independent of industry. The ultimate aim of lean is to find and eliminate or alter any part of a process that does not provide value. It allows faster answers to changing consumer needs, resulting in speedy and resilient production and higher quality at reduced costs.
Manufacturing in Industry 4.0 is made up of shared data, autonomous and intelligent machinery, and manufacturing units operated remotely. As a result, machines and equipment will achieve high levels of self-optimisation and automation. In addition, the manufacturing process will be able to fulfil more complex and competent product standards and requirements.
‘Intelligent manufacturing’ and ‘smart production’ are two of Industry 4.0’s primary goals. Intelligent production systems and processes, as well as engineering approaches, will be important for efficiently integrating distributed and networked production facilities in future smart factories. These smart factories respond to client requests for customised items using technical enablers such as the Internet of Things (IoT), cloud computing, mobile devices and Big Data, 3D Printing, and others.
Achieving intelligent identification
Recent manufacturing sector breakthroughs have paved the path for a systematic deployment of Cyber Physical Systems (CPS), in which data from all key perspectives is closely monitored and synchronised between the physical factory floor and the cyber computational world. For easy and rapid data interchange, intelligent production systems are integrated in a Cyber Physical Production Systems (CPPS) environment.
Radio frequency identification devices (RFID), infrared and laser sensors, global positioning systems, and other arbitrary objects that are connected to the internet using an agreed-upon protocol for communication help to achieve intelligent identification, location, tracking, monitoring and management.
Mobile and cloud computing, when combined with industrial IoT networks, enable powerful and accurate data & services for Industry 4.0. The IoT and Industry 4.0 will change how customers and producers interact.
Rapid rise in digitalisation
India is developing at a breakneck rate economically and leading the way for technology adoption and digitalisation. According to the World Bank’s most recent assessment of the Indian economy, digital revenue amounts for 30-32% of total revenue. The business sector is estimated to contribute $350-400 billion to India’s goal of building a $1 trillion digital economy over the next several years. 70% of end-user organisations, throughout the world, aim to considerably expand their digital investment in 2022, according to the NASSCOM Enterprise CXO Survey 2022.
According to a poll conducted by Infosys Knowledge Institute: By 2020 and 2021, more than 90% of organisations will have begun to implement some type of digital initiative in their workplace. The adoption rate in the industrial sector increased from 81–97%. It’s probable that the adoption rates are greater than usual due to the digital transition enforced by the pandemic.
Creating intelligent manufacturing
Biesse has made measures to create a precedent for intelligent manufacturing in the woodworking industries in conjunction with Accenture. SOPHIA was created to make work management easier and more logical, i.e., more Lean. It features a continual connection to the Biesse control centre, the option to seek assistance via the customer app (with requests prioritised), as well as diagnostics and performance checks.
IoT delivers a full view of machine performance through remote diagnostics, machine stoppage analysis, and failure prevention. When Biesse Service employs SOPHIA, it can inspect machine data directly, ensuring that it has all of the information it needs when communicating with the consumer. This also increases customer service efficiency.
The platform allows for the automatic generation of a spare parts shopping basket after monitoring the machine component status and getting information of the need for intervention. The consumer can choose whether or not to confirm the order and monitor indications related to machine productivity and particular parameters for the kind of machining operation in order to maintain a constant level of performance and enhance machining cycles. If required, the client may video chat with Biesse Service using their smartphone, allowing Biesse Service to view what the customer is viewing.
Making machine maintenance easy
The service network is available at all times for interconnection and individualised support, from error notice to resolution. From task notification to automatic creation of the online cart on PARTS, which is a function of SOPHIA, machine maintenance has been made easier. SOPHIA creates the spare parts purchasing basket in real-time, checks the price list and warehouse availability, and tracks the transaction from beginning to end. The platform can also provide a list of suggested or emergency spare parts.
SOPHIA even has features for machines that are not connected. Overall, the digital transition has aided in the attainment of lean manufacturing.