Industry 4.

0 Evolution,Maturity Levels, and

Applications
Hamza Javed College of Electrical and Mechanical
367747 Egineering
Industrial Control and Automation
Department of Electrical Engineering
 Abstract— The advancement of industrial revolutions has B. Industry 2.0(Late 19th to Early-20th Century)
fundamentally reshaped manufacturing, evolving from steam-
 Technologies : Electricity, assembly lines, electric
powered mechanization to autonomous, data-driven systems.
motors.
Industry 4.0, the latest phase, integrates cutting-edge
technologies such as the Internet of Things (IoT), artificial  Workings : Electricity enabled continuous power
intelligence (AI), big data analytics, and cloud computing to distribution, driving motors and conveyor belts for
enhance industrial efficiency, flexibility, and sustainability. mass production.
This paper examines the historical evolution of industrial
revolutions, the structured maturity levels of Industry 4.0  Attributes : Standardized parts, high throughput,
adoption, and its applications in various sectors. A five-level reduced labor per unit.
framework is presented, illustrating the transition from
manual operations to fully autonomous systems. Case studies  Impact : Ford’s assembly line reduced Model T
from leading industries, including Bosch, Toyota, Siemens, and production time from 12 hours to 1.5 hours, a
Tesla, demonstrate the practical implementation and benefits productivity gain of 88% [2].
of Industry 4.0 technologies. The findings highlight the  Mathematical Formulation: Production
significance of digital integration in modern industrial control
and automation systems, emphasizing its role in optimizing
P=N/T
productivity, predictive maintenance, and intelligent decision- Rate, where N is units produced, and T is time. For
making.

Ford, P before = 1/12 vs Pafter = 1/1.5 showing an 8-

I. INTRODUCTION
fold increase.
The evolution of industrial revolutions has dramatically
transformed manufacturing, shifting from steam-powered C. Industry 3.0(Late 19th to Early-20th Century)
mechanization to intelligent, autonomous systems. Industry  Technologies : Computers, programmable logic
4.0, the latest phase, integrates digital technologies such as controllers (PLCs), robotics.
the Internet of Things (IoT), artificial intelligence (AI), and
big data analytics to enhance efficiency, flexibility, and  Workings : Computers processed binary
sustainability in industrial processes. Understanding this instructions, while PLCs automated control loops
transformation requires analyzing both the historical (e.g., PID controllers)
progression of industrial revolutions and the structured levels  Attributes : Digital precision, automated workflows,
of Industry 4.0 adoption. flexible production.
 Impact : Reduced error rates by 30–40% in
II. COMPARISON OF INDUSTRIAL REVOLUTIONS electronics manufacturing [3].
Industrial revolutions have transformed manufacturing  Example: IBM’s use of computers in the 1960s for
through successive technological advancements, as inventory management.
illustrated in Figure 1:
D. Industry 4.0(Earrly 21st Century to Present)
 Technologies : IoT, AI, big data analytics, cloud
A. Industry 1.0(Late 18th to Mid-19th Century)
computing, 3D printing.
 Technologies : Stream engines, mechanical looms
 Workings : IoT connects devices via sensors (data
 Workings : Steam power converted thermal energy rate
into mechanical work, driving machinery via
pistons and gears.
 Attributes : Mechanized production, labor- D=B/T
intensive, low scalability. where B is bytes and T is time), AI optimizes via
machine learning, and big data enables predictive
analytics.
 Attributes : Real-time connectivity, intelligent
decision-making, sustainable production..
 Impact : Reduces downtime by up to 50% through
predictive maintenance [4].
 Example: Smart factories like Siemens’ Amberg
plant, processing 15 million data points daily [9].
Figure 1: Industrial Revolutions Timeline [5]

 Impact : Shifted production to factories, increasing III. LEVELS IN 4.0 INDUSTRY

output by approximately 50% in textile industries
[1]. Industry 4.0 adoption follows a five-level maturity
 Example: British textile mills, where steam- model, reflecting progressive digital integration, as shown in
powered looms replaced hand- weaving. Figure 2.
A. Level 1 : Initial/Ad-hoc  Metrics : Autonomy Level
 Workings : Manual processes with sporadic digital
use (e.g., standalone PLCs).
 Attributes: Low connectivity, minimal data
utilization
 Metrics : : Automation level
A=Ta/Tt  0.1
(where Ta is automated time, Tt is total time) [6].

B. Level 2 : Defined
 Workings : Basic digital tools (e.g., ERP systems)
collect data, but integration is limited.
At=Ta/Tt  0.9
 Attributes: Structured processes, initial automation.
(where Ts is self-managed time) [10].
 Metrics : Data Usage
Du=Dc/Dt  0.3
Figure 2: Industry 4.0 Maturity Model [11]
(where Dc is collected data, Dt is total data) [7].
Fig. 2 illustrates this progression, providing a
framework for assessing digital maturity [11].
C. Level 3 : Integrated
 Workings : Systems connect via IoT, enabling data IV. APPLICATIONS AND EXAMPLES
sharing across production stages
 Attributes: Horizontal/vertical integration, real-time Industry 4.0’s maturity model is applied across
monitoring. industries, with detailed examples for each level:
 Metrics : Connectivity
A. Level 1: Bosch (Small-Scale Plants)
C=Nc/Nt  0.6  Applications: Bosch’s legacy plants in rural
(where Nc is connected nodes, Nt is total nodes) [8]. regions still rely on manual assembly and paper-
based tracking for components like automotive
D. Level 4 : Optimized sensors.
 Workings : AI and analytics optimize processes  Details: Limited automation (e.g., standalone CNC
(e.g., predictive maintenance reduces downtime: Td machines), no integrated data systems, reflecting
= Tp · (1 − Pf), where Tp is planned time, Pf is initial stages [6].
failure probability).  Context: Common in smaller Bosch facilities
transitioning from Industry 3.0, as noted in Bosch
 Attributes: Data-driven, proactive adjustments. Industry 4.0 Transition.
 Metrics : : Efficiency Gain
Eg=Tb-Ta/Tb  0.4 B. Level 2: General Electric (GE Activation)
 Applications: GE Aviation uses ERP systems (e.g.,
(where Tb is baseline time, Ta is optimized time) [9].
SAP) and IoT sensors to monitor jet engine
production, collecting data on temperature and
E. Level 5 : Leading/Automous pressure.
 Workings : Fully autonomous systems self-optimize  Details: Data is stored but not fully analyzed in
using AI and robotics. real-time, with automation limited to specific tasks
 Attributes: Minimal human intervention, self- (e.g., robotic welding), achieving Du ≈ 0.35 [7].
correcting loops.  Context: GE’s early Industry 4.0 adoption, as per
GE Digital Transformation.
C. Level 3: Toyota
 Applications: Toyota integrates digital tools with
its lean manufacturing system, using IoT for
quality control and maintenance scheduling in
plants like Toyota City.
 Details: Sensors track production line
performance, feeding data to centralized systems
(connectivity C ≈ 0.65), enhancing defect detection
by 20% [8].
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Figure 4: Siemens’ Digital Twin Setup [9] [8] J. Green, "When the Toyota Way Meets Industry 4.0," IndustryWeek,
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 Details: Automation covers 90% of tasks (Al ≈ 24, 2025].
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Figure 5: Tesla’s Robotic Assembly Line [10]

V. SUMMARY OF FINDINGS
Industry 4.0 advances its predecessors by integrating digital
technologies, achieving efficiency gains (e.g., Eg = 0.4−0.5
at higher levels) and enabling customization. The maturity
model guides adoption, with Bosch and GE showing early
stages, Toyota and Siemens exemplifying integration and
optimization, and Tesla pushing autonomy— though its
challenges underscore human-technology balance. These
insights enhance understanding of industrial control and
automation systems
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