Module 1

Introduction
Industry 4.0 is a revolutionary method of organization of
industrial production, based on wide digitization and
automatization of production and distribution
processes in industry that erases limits between physical
objects, turning them into a comprehensive complex
system of interconnected and interdependent elements.
basic characteristics of Industry 4.0
Transition from manual labour to robototronics, which
ensures automatization of all production processes.
Modernization of transport and logistical systems, caused
by mass distribution of unmanned vehicles;
Increase of complexity and precision of manufactured
technical products, manufacture of new construction
materials due to improvement of production technologies;
Development of inter-machine communications and self-
management of physical systems, conducted with the
help of “Internet of things”.
Application of self-teaching programs for provision of
constant development of production systems.
Conceptual approaches to treatment of the
notion “Industry 4.0”
The socio-oriented approach emphasizes the fact
that development of Industry 4.0 strongly influences
the modern society and has positive and negative
manifestations.
On the one hand, Industry 4.0 allows creating new
goods, thus stimulating the increase of population’s
living standards.
On the other hand, reduction of human’s
participation in production processes may lead to
mass unemployment, which is a restraining factor on
the path of development of Industry 4.0.
The competence-based approach envisages
that development of Industry 4.0 requires new
competences from a modern industrial specialist.
Structural changes — replacement of manual
(physical) labor by intellectual—are also
accompanied by qualitative changes—servicing
self-managed physical production systems
requires from a modern industrial specialist
possession of new competences, which include
knowledge and capability to use new information
and communication technologies.
Within the production approach, development
of Industry 4.0 means modernization of industry
with large-scale automatization of the
production processes.
The behaviorist approach focuses on the fact
that development of Industry 4.0 envisages
transition to the object-object interaction, i.e.,
elimination of the subject (human) from the
system of interrelations of inanimate objects
(technical devices)
New Definition for Industry 4.0
“Industry 4.0”, is a new industrial model,
peculiar for self-organization and self
management of fully automated, self-teaching,
and interactive production systems, in which the
core is new digital and Internet technologies,
and the role of human is limited by their initial
start, control, and technical maintenance, which
requires from modern industrial specialists new
competences and is accompanied by social
changes.
EFFECTS IN ECONOMY
The process of formation and development of
Industry 4.0 influences all spheres of the economic
system, including the social sphere, which is peculiar
for substantial changes related to the necessity for
adapting human to new conditions of economy.
Thus, entrepreneur optimizes business processes,
using the possibilities provided by Industry 4.0,
The employee (industrial specialist) either masters
new competences, which are necessary in Industry
4.0, or looks for a job in another sphere, and
consumer masters new industrial products.
Genesis of Industry 4.0
A well-known philosopher and sociologist of the 20th
century Alvin Toffler distinguished three “waves” in
developed society: agrarian revolution, transition to
industry, and transition to society that is based on
knowledge.
Professor of social sciences Danial Bell, who is
known also as one of the leading American
intellectuals of the post-War period, distinguished
the following industrial revolutions: steam engine
and railroad transport (late 18th century);
electrification, division of labor, and mass production
(late 19th century); electronics, IT industry, and
automatized production (late 20th century).
Development of Industry 4.0
First Industrial Revolution or Industry 1.0 -
With the invention of steam engines in the
seventeenth century lead to the change the
process of manufacturing in eighteenth century
in Britain by using the basic materials like iron
and steel using motive power (Steam engine)
and fuels (Coal, Petroleum) as the energy
sources lead to new beginning of manufacturing
process.
Second industrial revolution - At the end of
the nineteenth century, with the invention
electricity started the second industrial
revolution. It’s also known with the name of
technological revolution, as it set the footprints
for various technologies. It was during the time
of second revolution, that railroads, paper
making, synthetic dye, petroleum refining
industry.
The third industrial revolution was inspired
by the innovations in the electrical engineering.
As it was inspired from the digital electronics, it
is also known as the Digital Revolution.
Industry 4.0 or the fourth industrial revolution
is a revolution which will change how we look at
the development process, it is not just easing the
process it is changing our life too. The
revolutions till now has improved the working
efficiency of the machines and lead to the mass
production.
Technology developments in Industry 4.0
Key objectives of Industry 4.0
IIOT- Industrial Internet of things (IIOT) is
associated with the concept of virtual world.
Industry 4.0 look forward to increasing use of
Internet and IOT for achieving enhanced human-
machine interactions that could further enable
intelligent manufacturing, thus aiding the fourth
industrial revolution. Blending of the physical world
with the virtual world has been made possible with
the help of technological innovations in the field of
IOT that could possibly accomplish things talking to
each other. It includes laser scanners, global
positioning systems, sensors etc.
Link: https://youtu.be/AQdLQV6vhbk
Additive manufacturing - This often includes 3D
printing etc. that are used for production of
individual components. With the augment of
Industry 4.0, this technology would gain fruitful
impact and boost the production of customized and
personalized products by the manufacturers.
Artificial intelligence - Artificial intelligence is a
science that deals with the adaptive and collective
intelligence for extracting valuable amount of real
time information as and when needed using efficient
tools and technologies including machine learning,
population based heuristic algorithms, deep learning
etc.(https://youtu.be/NbEbs6I3eLw)
Agility and sequencing - It is a method of
manufacturing that encapsulates the sequencing
mechanism where for any specific configuration,
its parts arrive at a production line at the apt
time as per customer-centric configuration
details. It is quite analogous to just-in-time
sequencing methodology.
Cloud computing- These are quite compatible
for dynamic memory allocation and resource
sharing etc. Hence, enabling users to use the
cloud resources as per their needs including
hardware, software, infrastructure resources etc.
Big data, data mining and data analytics- Big
data analytics is a process that involves collecting,
processing, and analysing large amounts of data
from various sources. The goal of big data analytics
is to uncover hidden patterns and correlations that
can help organizations identify opportunities and
risks.
Augmented reality- Different variety of services
including selection of parts in warehouse, conveying
instructions related to repair of the mobile devices
etc. are provided with the help of augmented reality
based systems. They aim to furnish the real time
information that could be used by workers etc. for
effective and efficient decision making procedures.
MES/SCADA - It is called as Manufacturing
Execution Systems/Supervisory Control And
Data Acquisition. It entails the shop floor
monitoring with real time data collected by
using SCADA and remote control of production,
transforming long term scheduling in short term
orders with MES.
Additive Manufacturing
It is also known as 3D printing technology which is
mostly used to prototype and produce products in
small quantity.
Additive manufacturing is capable of providing a
layer wise additive method to manufacture products
having complex design and shape with a large
variety of materials.
Reduced cost of programmable controllers, lasers,
inkjet printing, sophisticated CAD software, etc.
catalysing the further growth of the additive
manufacturing technology.
It has the capability to influence the traditional
system of production models in terms of
machinery, assembly processes, and supply
chains of industry.
Design flexibility, the realization of complex
geometric shapes, dimensionally accurate
product manufacturing, removal of multiple
parts assembly, time and cost efficiency in
production run are some of the vital capabilities
of additive manufacturing which outweigh the
conventional production system.
Additive manufacturing is expected to be the key
technology for manufacturing highly customized
products due to its ability to design and produce
sophisticated goods, thus offering the highest
level of customer satisfaction.
Role of Robotics and Automation
in Industry 4.0
Robots play an important role in modern
industry that can complete their tasks
intelligently, with their focus on safety, flexibility
and collaborative.
Robotics and industrial automation has
completely changed the production and
manufacturing phase.
Both are working in implementing automation
to increase production and hence the economy.
Robotics brings several engineering areas and
skills together.
Industry 4.0 also known as digital industrial
technology; is completely a new phase in Market
Revolution in which focus is on Machine
Learning, Automation, Robotics and Real time
data.
Robotics is part of the Industry 4.0 which is the
market for smart machines, including expert
systems, autonomous robots and digital
assistants.
The aim of Industry 4.0 in Robotics is mainly to
develop a smart industry in which products can
find their own way through production and can
establish alternatives in case of any
disturbances.
Automation or Intelligent factory means big data,
robotics, high end IOT chips and in which
everything is connected wirelessly.
Ability is to communicate with each other and
have ability to control each other.
The development of new technologies like ICT
technologies, sensor and their application in robotic
technology leads to the development of new robots that
can work with the workers.
Robotics is the foundations of the fourth industrial
revolution.
Robots increases productivity, they use sensors and
actuators to produce accurate and strong data, but the
main fact is no robot has any future unless it is
integrated in to network system based on latest
technologies.
“Smart factory” are future and evidence suggest that
future factories will be fully automated and robotized.
These factories will become a highly efficient
manufacturing location, with machines at different
production stages and logistics systems that permanently
exchange information without human interference so
much.
Mass customization is one of the key goals of the
Industry 4.0.
Modern industrial production outfits utilize up-to-
date image processing systems for quality
management purposes.
Automation and robotization also affect people’s
working lives and fundamentally changing the
workplace.
Robots are becoming more independent, cooperative,
and flexible.
They will work with humans and interact with one
another and will learn from them.
Automation plays an important role in any
factory for manufacturer on their way to
Industry 4.0 implementation.
Automation provides a boost for industrial
automation.
Manufacturing systems are designed keeping
long term profit in mind.
If manufacturers want to be competitive in
market, they have to improve both products and
the production systems continuously.
 Industrial robots models

Types of mobile robots

Industry 4.0 production system
National Institute of Standards and Technology
defines smart manufacturing as fully integrated,
collaborative manufacturing systems that respond in
real time to meet changing demands and conditions
in the factory, in the supply network and in customer
needs.
Adopting Industry 4.0 requires both vertical and
horizontal integration of data across the business.
Vertical digitalization may include production,
procurement, supply chain, design, product life cycle
management, quality, operations and logistics.
Horizontal digitalization may include data
integration with customers, suppliers and key
partners.
Efficient data services and analytics is also a
major requirement of production to convert the
information being generated by the machines,
sensors and systems into insights which can
provide an investment return.
Most of the changes which are happening in
production are focused on customization.
Consumer involvement has increased in
Industry 4.0.
To cope up with Industry 4.0, manufacturers should
invest in training, automation of processes, devices
and software.
3D printing is an example of an entity which has the
potential to realize Industry 4.0.
In spite of being a very simple technology, it can
make huge transformations in modern production.
A 3D printer enables one to take a digital blueprint
which gets into the system as an input and the
system transforms the same to be used by printer.
Then, the physical printer develops the item which
has been detailed.
This is done using materials such as hard ABS
plastic, metal, concrete and more.
Cloud Manufacturing
The manufacturing capabilities and resources
can be shared on a cloud platform.

Eg: AWS
Internet Manufacturing
Interaction between the connected systems takes
place using standard internet protocols and have
the ability of self-configuration, prediction of
failure, and adapt to desired changes.
Cyber manufacturing utilizes a systematic
approach for manufacturing operations with the
involvement of internet technology to achieve
the functional objective of an enterprise with
increased productivity and reduced downtime.
Virtual Manufacturing
It is a process which utilizes computer-aided design
environment to manufacture products.
It provides a computer-simulated environment of the
actual manufacturing process with the help of virtual
reality.
It has the capability to provide a better
understanding of a process without making of
prototype models, reduce time in product and process
development cycle, eliminates material waste and
faulty design.
The virtual manufacturing process helps to train a
new operator quickly in comparison to the
conventional manufacturing system, thereby
reducing the wastage of machine time.
Lean Manufacturing
Lean Manufacturing is a systematic approach to
minimize waste from production without
compromising the production capacity and quality.
It actually works relentlessly on eliminating waste
from a manufacturing process.
In the past, Toyota Motor Corporation has
implemented lean manufacturing successfully and
displayed appreciable enhancement in productivity
and decrease in wastes in its firm.
Agile Manufacturing
Agile manufacturing refers to an approach which
enables an organization to develop an internal
process and supporting environment to leverage a
competitive advantage over its competitor in the fast-
changing market place.
Such an organization can respond quickly to the
changing needs of the customer and market still
maintaining the consistent quality at a competitive
cost.
Global readiness towards
Industry 4.0
Networked readiness Index is a key indicator of how
countries are doing in the digital world.
It depends on whether a country possesses the
drivers necessary for digital technologies to meet
their potential, and on whether these technologies
are actually having an impact on the economy and
society.
The digital revolution may change the nature of
innovation, which is increasingly based on digital
technologies and on the new business models it
allows.
The 2016 Index has highlighted a number of key
issues such as-
⚫ increasing pressure to innovate technology,
⚫ trailing out of rapidly growing digital population by
businesses and companies,
⚫ developing of new types of behaviour,
⚫ leadership and governance mechanisms etc.
⚫ to adopt digital technologies and to capture the growing
market.
The (World Economic Forum) WEF’s report makes it
very clear that there is huge gap between developed
nations and developing ones because of many factors.

It says that the digital economy has divided the

developed countries and developing nations into two
segments.
India’s Readiness for Industry 4.0
The vision of making India a manufacturing and
export powerhouse started many years ago as away
to reduce the dependence on imports and change
India's status to that of a global manufacturer
capable of manufacturing in-house and supplying to
the rest of the world.
Initiatives and campaigns like 'Make In India' and
'Aatmanirbhar Bharat' were launched to boost the
manufacturing industry and increase its
contribution to India's Gross Domestic Product
(GDP) to 25% by 2025.
As of now, the contribution stands at 16%.
The Design-linked Incentive (DLI) for the
semiconductor industry or the Production-linked
Incentive (PLI) for the automobile sector, and the
introduction of more such schemes, will, in time,
encourage enterprises of all sizes to take up Industry
4.0 technologies, but incrementally.
Additionally, the Smart City mission and initiatives
under the Samarth Udyog Bharat, including the
work done through the Center for Industry 4.0 (C4i4)
Lab, are slowly raising awareness, and creating a
collaborative space for stakeholders to test out
capabilities.
 Design-
linked https://chips-dli.gov.in/DLI/HomePage
Incentive
(DLI)
Ministry of New and Renewable Energy,
Government of India is implementing
the Production Linked Incentive (PLI)
Scheme for National Programme on
Production- High Efficiency Solar PV Modules, for
linked Incentive achieving manufacturing capacity of
(PLI) Giga Watt (GW) scale in High Efficiency
Solar PV modules with outlay of Rs.
24,000 crore.
Smart City
mission
India’s first smart factory, moving from automation
to autonomy, where machines speak with each other,
is being set up in Bengaluru.
It is making progress at the Indian Institute of
Science‟s (IISc) Centre for Product Design and
Manufacturing (CPDM) with an investment from
The Boeing Company.
A smart factory, armed with data exchange in
manufacturing and the Internet of Things (IoT) is
the future and experts are calling it revolution
Industry 4.0.
Reports peg the smart factory industry to touch US$
215 bn by 2025 and all major economies are likely to
accept it.
Challenges
In the case of manufacturing units located in remote
towns, poor internet connectivity and network
coverage affects the communication ability of devices
and thereby, the transfer of data.
But there is still hope as the 5G spectrum promises
to improve last-mile connectivity.
In the case of data security, manufacturers have to
deploy strong cybersecurity policies to counter any
cybersecurity and privacy issues.
STRENGTHS
India’s strengths over others:
⚫ A growing working population and an expanding
middle-class are expected to remain key demand
drivers.
⚫ India has the world’s 12th largest number of high-
net- worth individuals, with a growth of 20.8%, the
highest among the top 12 countries
⚫ Disposable incomes in the rural Agri-sector shows
increasing trends
⚫ There is a presence of a large pool of skilled and
semi-skilled workers and a strong educational system
INDUSTRY 4.0: ITS ACCEPTANCE IN
AUTOMOTIVE INDUSTRY IN INDIA
Automation in India was first started by Bajaj
Autos.
Ford is using over 400 robots to operate the
manufacturing product line at its Sanand Plant.
Hyundai has also reduced its labor cost by
making use of more than 450 automatic robots
in their manufacturing plant.
Advantages of Make in India initiative to
Automobile industry of India:
⚫ 360 degree ease of doing business
⚫ Cost advantage to local manufacturers
⚫ Quicker movement of new vehicles
⚫ Boost to electric vehicle industry
⚫ Fall in vehicle prices