INDUSTRY

Why it matters?
4.0
The better the question. The better the answer.
The better the world works.
from Things

Connecting the unconnected & digitizing the analog

3D Printing 44
reduces the zettabytes
repair times for of data
around 90%

80% of
<1% of IoT eliminated,
data is being reinvented process
used 50b connected
devices
80% lower
prices of wireless
tech. vs. 4 years
ago

*Source: Gartner – “Top 10 Tech Trends for 2013” – 2012, Economist Intelligence Unit – ”The Rise of the Machines”, IDC FutureScape: Worldwide Internet of Things 2015
Predictions
** McKinsey – Unlocking the value of the Internet of Things Report, June 2015

to Outcomes
Agenda

► Industrial Evolution
► 4th Industrial Revolution
► Building Blocks of Industry 4.0
► Potential Industrial Products Implications
► Potential Consumer Products Implications
► Impact of Industry 4.0
What is this?
Presentation title
What is this?
What is this?
What is this?
Is it Evolution or Revolution? – A Million Dollar
Question
Evolution Revolution

Early Carriage Early Automobile

More Fancy
Carriage

Evolution Revolution

Vintage Analog Fancy Digital Phone Smart Internet Phone

Phone

• Evolution - A gradual process in which something changes progressively from

one stage to another
• Revolution - A total turn around; a sudden, complete, or fundamentally radical
change in something
• Typically, Revolution leads to further Evolution – For example, Invention of
Automobile was Revolutionary however innovations such as Ground Mail and
Commercial Transportation evolved Automobile invention into a Commercial
Enterprise
Industrie 1.0…
Industrie 2.0…
Industrie 3.0…
Industry 4.0…?

Mobile
phones
Volume CD
player
s
Cars

Trucks

Airplanes

Hightech Equipment

Complexity
Industrial Evolution

4. Industrial
revolution
Based on cyber-physical-
systems

3. Industrial revolution
Through the use of electronics
and IT further progression in
autonomous production

2. Industrial revolution

Level of complexity
Introducing mass production
lines powered by electric
energy

1. Industrial revolution
Introducing mechanical
production machines powered
by water and steam
Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0
End of the Beginning of the Beginning of the Today
18th century. 20th century 70th
Source: DFKI/Bauer IAO
Towards Intelligent Environments based
on the Internet of Things and Services
5) Intelligent
Environments Smart Factory

4) Embedded Computers

1) Central Computer
2) PC, Notebook 90% of all
3) Smart Phone
computers are
Smartcard
embedded

1 Computer
Many Users 1
Computer Many Computers, 1 User
1 User

1941 1960 1980 2000 2020

The 4th Industrial Revolution
one
Trillion internet
*1 connected IoT

devices by 2025
Data to Increase by
10x over the next 4 years *2
Velocity, Scope and Systems
Impact
*1 No Ordinary Disruption: The four forces breaking all the trends
*2 IDC’s Digital Universe study
 Global transformation on Industrial Revolution 4.0

Connected Mobility

Smart Production
Smart Retail

Physical Digital

Fusio
n 4.0

Home Biological Smart Decision

Automation

Edutech Medtech

Smart
Logistics
Courtesy: www.weforum.org 2016 - the-fourth-industrial-revolution-what-it-means-and-how-to-respond
 Data is the Next Oil
Mukesh Ambani, 2017

Oil Wells Data Sensing

and generation

Oil Production
Data collection

Refinery
Data Analytics

Transportation Data Centre &

Storage

IoT
Pump Intelligence of Things
Transformation to 4.0
Disruptive
Don’t innovate to stay competitive….. Technologies
Innovate to change the rules of the game Make
electronics
for Non-
Electronics

Creating Intelligent
Products

Design led mfg.

25% of tech workforce will be contingent

Factory 50% of business app will be in cloud

Mgmt. &
Operations
80% of all process will be eliminated
 Courtesy: Re-imagining Manufacturing, CII, Santhanam
MD Saint Gobain India
Technology Continues to Evolve…

… from Stethoscope to Augmented

Reality

Intensive Manual labour to Robots

and Cobots…

Manual to Smart
Automation…
VW Industry 4.0
1957: 13 men delivering a computer

2017: a person may wear 13 computing devices

23
Phases of Earlier 3 Industrial Revolutions

1. 1760 to 1840 - Ushered in Mechanical production; railways and

steam engine

2. 1870 to 1940 - Mass production; electricity and assembly line

3. 1960 to 2010 - Computers; semi conductors, main frame computing,

personal devices, internet
Industry 4.0: Germany
Smart Manufacturing Leadership Coalition: USA

A collective term for technologies and concepts of value chain organization. Based
on the technological concepts of cyber-physical systems, the Internet of Things and
the Internet of Services, it facilitates the vision of the Smart Factory.
Within the modular structured Smart Factories of Industry 4.0, cyber-physical
systems monitor physical processes, create a virtual copy of the physical world and
make decentralized decisions.
Over the Internet of Things, Cyber-physical systems communicate & cooperate with
each other & humans in real time. Via the Internet of Services, both internal & cross-
organizational services are offered & utilized by participants of the value chain.

 Builds on the Digital revolution  Ubiquitous internet

 Smaller & powerful sensors  Artificial Intelligence (AI)

 Machine Learning  Labor & Energy Cost

Industry 4.0

• Machine-to-machine and machine-to-workpiece

communication
• Use of bluetooth and wifi
• Application of artificial intelligence
• Less human intervention
Did not exist in 2006

► iPhone ► Android

► iPad ► Oculus

► Kindle ► Instagram

► 4G ► Snapchat

► Uber ► Whatsapp

► Airbnb ► Grab

► Android ► Expedia
Time to reach 100 Million customers

► Telephone 75 Years

► Web 7 Years

► Facebook 4 Years

► Instagram 2 Years

► Pokemon Go 1 Month
Cyber Physical Systems

A cyber-physical system (CPS) is a system of collaborating computational

elements controlling physical entities. CPS are physical and engineered
systems whose operations are monitored, coordinated, controlled and
integrated by a computing and communication core. They allow us to add
capabilities to physical systems by merging computing and communication with
physical processes.
Today’s Factory
Tomorrow’s Factory
Industry 4.0
Six Design Principles
► Interoperability: the ability of cyber-physical systems (i.e. work
piece carriers, assembly stations and products), humans and Smart
Factories to connect and communicate with each other via the
Internet of Things and the Internet of Services
► Virtualization: a virtual copy of the Smart Factory which is created by
linking sensor data (from monitoring physical processes) with virtual
plant models and simulation models
► Decentralization: the ability of cyber-physical systems within Smart
Factories to make decisions on their own
► Real-Time Capability: the capability to collect and analyze data and
provide the insights immediately
► Service Orientation: offering of services (of cyber-physical
systems, humans and Smart Factories) via the Internet of Services
► Modularity: flexible adaptation of Smart Factories for changing
requirements of individual modules
Building Blocks of Industry 4.0

Autonomous
Robots

Big data
Simulation
analytics

Horizontal
Augmented and vertical
reality Industry 4.0 system
integration

Industrial
Additive Mfg Internet of
Things
Cyber
Security
Impacting all aspect of value chain
Digital Enterprise
Entire value chain is digitized and integrated
Potential Implications

Robot assisted production

Predictive maintenance

Additive manufacturing of complex parts

Machines as a service

Big data drive quality control

Production line simulation

Smart supply network

Robots working in Amazon warehouse

45000
40000
35000
30000
25000
20000
15000
10000
5000
0
2013 2014 2015 2016
Examples
SIEMENS

German manufacturing giant Siemens, an industrial user, is

implementing an Industry 4.0 solution in medical engineering. For years,

artificial knee and hip joints were standardized products, with engineers

needing several days to customize them for patients. Now, new software

and steering solutions enable Siemens to produce an implant within 3 to

4 hours.

Source: Think Act: INDUSTRY 4.0 The new industrial revolution How Europe will succeed
Examples
TRUMPF

German toolmaker Trumpf, an Industry 4.0 supplier and worldwide market

leader of laser systems, has put the first "social machines" to work. Each

component is "smart" and knows what work has already been carried out

on it. Because the production facility already knows its capacity utilization

and communicates with other facilities, production options are

automatically optimized.

Source: Think Act: INDUSTRY 4.0 The new industrial revolution How Europe will succeed
Examples
GE
Predix, the operating system for the Industrial Internet, is powering

digital industrial businesses that drive the global economy. By

connecting industrial equipment, analyzing data, and delivering

real-time insights, Predix-based apps are unleashing new levels of

performance of both GE and non-GE assets.

Source:https://www.ge.com/digital/predix
Examples of Product evolution: Connected
and smart products

Harvard Business Review

Internet of Things - Evolution
Internet of Things
components?
Things Connectivity Data Analytics
The Internet of Things

A fabric that (is going to) connects every object in the world
Two Views or Ends

We need research on both of these (and jointly)

IoT Devices & Networks

IoT Data Analytics
IoT Devices

An electronic device that augments lifeless objects with the

capability of sensing, intelligence, and communication.

IoT devices are often called “smart” devices, but we should not
Smart* - the most misused term

► “Smart” devices should contain an OS that runs Apps.

smart IoT
Why IoT is happening now?

► Advancements in: (1) sensor technology, (2) miniature

computers, (3) low-power wireless communication, (4)
mobile devices, and (5) cloud.

Accelerometer Pulse Sensor

Intel Joule 570X Bluetooth LE
(1.7 GHz, Quad-Core, 4 GB (up to 2 years
RAM, 16 GB storage) lifetime on a
single coin-cell
(2) battery)

Force Sensor VGA Camera (3)

(1)
Idea: Move from Internet of People  Internet of Things

Internet appears everywhere in the  Internet of Things is a plan to

world connect things also using the same
 It is primarily connection between people medium
IOT: People connecting with Things

ECG sensor

Internet

Motion sensor

Motion sensor
Motion sensor
IoT: Things connecting with Things

- Complex and heterogeneous

resources and networks
Looming Opportunity
IoT Applications : Shopping
Smart City
 CITIES ICT
Smart City
Definition • Green Infrastructure
• Energy
• Broadband
• Sensors
• Waste • Mobile Devices
• Water • Robotics
Smart Cities • Buildings • Data Centers

use information Hardware/

Urban
- Systems
Broadban
d
communication
technology
(ICT) to engage Software/
Social
citizens, to Systems Apps
deliver city • Citizens – Leaders • Social Media
services, and to • Economic
• Public Safety - Health
• Smart Grid
• Smart Meters
• Education • Smart Transportation
enhance urban • Neighborhoods • Big Data

systems.
ESSENTIAL COMPONENTS OF SMART
CITIES

Sustainability
- Resiliency
Broadband Governance

Applications
Equity
- Data
 Areas of WG2 Technical Reports

Open Data
Integrated
Smart
Management
Buildings

Smart Water Smart

Management Infrastructure

Climate
Change Cyber-Security and EMF
Adaptation Resilience considerations
Smart City visions

66
Smart City visions

67
Smart City Visions

68
 Different looks of SMART CITY

FEMS example:-
• Visualization
system
interconnected
with various
production
information such
Monitoring &
Control on a real
time basis

69 ….to be continued
Source: Toshiba Group
 Different looks of SMART CITY
Remote communication services for Education & Healthcare

70 ….to be continued
Source: Hitachi Group
 Different looks of SMART CITY
Shared use of neighborhood facilities

71 ….to be continued
Source: Hitachi Group
Smart Cities
Applications

Image Source: https://houston.bcycle.com

Seattle’s Smart Parking

Image Source: http://blogs.ridemetro.org

Smart Cities – Public Engagement

Image Source: MetroQuest

 Smart City: Green Buildings

Google: smart cities green buildings

http://www.gogreeninthecity.com/smart-
cities

http://www.greenliving4liv
e.com

APA Smart Cities MindMixer A path to enabling your city’s digital DNA comes from the use
of Building Information Modeling (BIM) and the data captured by
Smart Buildings. BIM and Smart Buildings provide the digital DNA
that when put into the context of a neighborhood, district and City,
provides a city relevant, authenticated data.
PAN CITY PROJECT

Smart Tumakuru Sustainability

City Governance
Better
Performance

Enhanced Quality of
Life
Transparency and
Accuracy
Integrated Resource Management & City
Governance 75
 PROPOSED COMPONENTS

Integrated Water & Waste

Water Management

Smart Metering for Water

Supply

LED Street lighting with

CCTV Surveillance

Smart e-Governance and

Quality Service Delivery
76
 PROPOSED COMPONENTS
Integrated Distress
Helpline Number

Citizens Feedback
Grievance System

Integration of Education
Institutions as Partner in
Development

Technology
Park/Incubation Centre
77
IoT Applications : Intelligent Home
81
Augmented Reality
IoT Analytics (Examples)

► Categories of applications include: (1) push

notifications, (2) predictive maintenance, and (2) real-
time stream analysis.

beacons
‘nearables’

https://www.rtinsights.com/iot-analytics-use-cases-tdwi/
 IoT Analytics (Examples)

► Categories of applications include: (1) push

notifications, (2) predictive maintenance, and (2) real-
time stream analysis.

US Air Force saved $1.5M ThyssenKrupp

through real-time vehicle predicts when to
tracking. repair elevators

https://www.rtinsights.com/u-s-air-force-sees-benefits-from-condition-based-maintenance/ 100
https://www.thyssenkrupp-elevator.com/en/
IoT Analytics (Examples)

► Categories of applications include: (1) push

notifications, (2) predictive maintenance, and (2) real-
time stream analysis.

http://www.fool.com/investing/general/2016/04/29/what-the-internet-of-things-means-for-car-companie.aspx
Putting them together

► An IoT system – consisting of {sensors, mobile devices,

computers, and the cloud} who will talk to each other
over {BLE and WiFi} as appropriate.

102
Self Driving Car or
Autonomous Car
IoT Applications : Transportation
Opportunities to Improve Safety
Connected Vehicles
 Opportunity: Connected Vehicles

Vehicle-to-Vehicle (V2V) Communications for Trucks

► Connected vehicle applications developed for truck platforms are
being designed to be interoperable with all other vehicle platforms.
► Examples of V2V safety applications for heavy vehicles include:
► Forward Collision Warning
► Blind Spot Warning/Lane Change Warning
► Intersection Movement Assist
► Electronic Emergency Brake Light
► In 2014, NHTSA announced an Advanced Notice of Proposed
Rulemaking (ANPRM) for V2V on Light Vehicles and has stated
their intent to make an agency decision on V2V safety technology
for heavy vehicles.
 Opportunity: Safety Applications

► Dynamic Speed Limits

► Dynamic downhill truck
speed warning system on I-
70 (Denver, CO)
► Variable truck speed limit on
I-84 (Pendleton, OR)

Source: ENTERPRISE Pooled Fund Study ↑ Source: Wyoming DOT ↓

► Dynamic Truck
Restrictions
► Wind warning for high
profile vehicles on I-25
(Wyoming)
 Opportunity: Traffic Signal Operations

► Freight Signal
 Opportunity: Dynamic Truck Parking

Source: Michigan DOT

► Smart Truck
Opportunity: Smart Truck Parking
Leveraging Connected Vehicle Technologies
 Opportunity: Eco-Driving

► Sensors can be used to track the

drivers' habits and provide real-time
feedback to drivers
► Fuel waste stems from hard
accelerations, hard braking, hard
turning, the inability to maintain a
constant speed, and excessive idling
► A 2011 report suggested that eco-
driving strategies could improve fuel
efficiency by up to 22 percent saving
commercial truck operators more than
$12,500 a year per truck
Source: SmartDrive Systems, whose products track individual
driving habits for fleet operators
 Opportunity: Catenary Systems

► The Ports of Los Angeles and Long

Beach’s e-highway concept consists
of an overhead catenary system
running along the outside lanes of
both sides of the road leading to the
port
► Specially outfitted hybrid or all-electric
trucks can attach to the system using
automated current-transfer devices
called pantographs (similar to
trolleys)
► Once connected, the trucks can pull
all their power from the overhead
lines, effectively becoming emission-
free vehicles
 Emerging Area: Automation

Fully and partially automated trucks, ships, and planes,

and automatic freight-transfer facilities, may eventually
transform the freight industry
Automated features to improve the safety and efficiency of freight
movement are already being introduced
► On trucks, initial automation systems combine adaptive speed
control, automatic braking, lane-departure warning systems, and
vehicle-to-vehicle (V2V) communications
► In the long-term, driverless cars could be used for last mile delivery
to deliver packages to centrally located, self-service stations
► At warehouses and ports, self-driving vehicles can load and
unload goods
 Opportunity: Automation at Ports

Automation is being used at

major container ports around the
world. The process of transferring
containers from ships to docks,
trucks, and trains is becoming
highly automated, reducing
reliance on human operators.
127
Presentation title
Automatic Guided Vehicle (AGV)

► Industrial material transportation

► Unmanned transportation vehicle
► Optical, wired or laser navigation system
► Forklift ,cart, unit load or towing versions
► High safety with traffic control system
► Wide range of usage
► Flexible system configuration
 Sensors in even the holy cow!

In the world of IoT, even the cows will be connected and

monitored. Sensors are implanted in the ears of cattle. This
allows farmers to monitor cows’ health and track their
movements, ensuring a healthier, more plentiful supply of milk
and meat for people to consume. On average, each cow
generates about 200 MB of information per year.
141
Remote Surgery
Patient-driven Monitoring – Wearable Device

► Integrated use of mobile apps will allow patient data to be

collected more frequently and more effectively, which may
facilitate improvement in quality of patient care.
► Patient-specific data from patient self-monitoring can be used
to make individualized diagnoses and/or treatment plans.
► Use of mobile apps and wearable tech may facilitate better
chronic disease management via more real-time
communication with patient and reduction of unnecessary
office visits.
► Use of patient-driven monitoring could impact population
health management via increased access to care.
Current IoT Landscape in
Manufacturing
from Things

Future of Manufacturing fosters a coherent stakeholder collaboration

Standardization & Manufacturers

Government engagement business networks

Industry 4.0 & IoT

Digital Technology solution

providers
Assets

to

Outcomes
from Things

Connected Manufacturing, connecting production systems to core business processes with an

end-to-end visibility

Challenges Value
Cloud Platform

65% 6h
Operations in Overall
Quality SAP Connected Effectiveness Delivery Time
Silos Requirements
Manufacturing

7-12%
Manual Supply Chain Cost
Compliance Reductions Traceability
Reporting

Infinite Plant Smart Data Augmented

Non- Insights Connectivity Streaming Reality
analytical IT-OT Product Process
Decisions Convergence S/4 HANA MII Manufacturing Execution Suite Network Optimization

to

Outcomes
Airbus – Factory of the Future

• MiRA (Mixed Reality Application) tablet

• Cross between a sensor pack and
a tablet

• Internet Connected Smart Tools

• Auto-adjust to different actions
• Log information
• Reduces assembly time

• Augmented Reality driven instructional

& educational tutorials

Photos courtesy of Airbus Factory of the Future

Siemens – Shampoo Plant

• Bottle carriers with RFID tags can talk to

machines in a production line
• Smart Dispenser Machine:
• Reads RFID info
• Determines type of shampoo to fill
• Knows how much shampoo to fill
• Smart Labeling Machine:
• Reads RFID info
• Determines if the bottle is filled
• Knows what label to put on the filled bottle
• Eliminates the need for human input in the
dispensing and labeling process
• Eliminates the need for a separate
production line for each type of shampoo
Continental AG’s SMART Factory

• Active RFID tags and Geo-

location are used to move the
tire components throughout the
factory

• Collaborative robots
• Robots are “shown” how to
do a task once and then
they can repeat that action
• Reduces risks of injuries
and reduces the need for
additional assisting
employees
What the Future Holds….
Streamlined Factories

► Sensors are
attached to
components,
forklifts, employees
and other assets
Streamlined Factories

• By geolocating the
sensors, one can
see how people and
products are moving

Processes can be streamlined and production time reduced.

SMART Inventory Management

► Sensors on containers can

determine when a product is
running low
► Employees will be alerted to
proactively re-order the parts
when a certain level is reached or
orders can be automatically
placed with suppliers

Components will not run out or run low

Reduced costs of production
More uptime for factories which leads to
higher productive levels
SMART Inventory Management

► Sensors can also be used to

determine if a container is
reaching its capacity. This could
trigger an alert for a forklift to
remove the container and
replace it with an empty one.
Can also be used for waste
management

Components will not overflow from a container

More uptime for factories which leads to higher
productive levels
SMART Quality control

► RFIDs attached to products can

be used to tag defective products
► If over a certain number, an
employee can be alerted to see if
there is a bad batch of
components or if an adjustment
needs to be made to the
machinery
► Employees can be alerted if the
problem is the result of a defective
part
► If an adjustment is needed, it can
be automatically made in real-time
Product quality is controlled and course corrections are made while
product is still moving through the production line
Manufacturing Revolution is shaping SMART
Factories….
• Smart factories are connected in a network
through the use of cyber-physical
production systems which lets factories and
manufacturing plants react quickly to
variables, such as demand levels, stock
levels, machine defects, and unforeseen
delays
• This networking also involves the smart
logistics and smart services
• The whole value chain in such
integrated network is subjected to
through-engineering, where the
complete lifecycle of the product
is traced from production to
retirement through the use of IoT
technologies
IOT TECHNOLOGIES
IoT Road Map
IoT Technologies

Hardware

Communication

Protocols

Software (IDE)

Cloud Platforms
 Implementing Smart Objects

Beaglebone
black

Intel Galileo

Raspberry Pi

Arduino Uno
Board Connection
Sensors and Actuators
Sensors available in Market
IoT Technologies : Communication Protocols
IoT Technologies : Protocols

CoAP ( Constrained Application Protocol)

MQTT (Message Queue Telemetry Transport)

RESTful HTTP (Representational State Transfer)

XMPP (Extensible Messaging and Presence Protocol)

IoT Technologies : Data Analysis
IoT Technologies : Cloud (Sensing as-a-service Model)
IoT Technologies : Cloud Providers

IBM BlueMix

AWS IoT

Azure IoT

OpenSensors

Verizon ThingSpace
Challenges of IoT
Technological Standardization in most areas still remains fragmented.

Managing and fostering rapid innovation is a challenge for

governments

Privacy and security

Absence of governance

Vulnerability to internet attack

176
Impact

Economy

Individual
Business
Impact

Society National
& Global
Impact
Economy

► Growth

► Ageing

► Productivity

► Employment

► Labour subsititution

► The nature of Work

Impact
Business

► Customer expectations

► Data enhanced products

► Collaborative innovation

► New operating models

Combining digital, physical and biological worlds

Impact

► National & Global

► Governments

► Countries, regions & cities

► International security
► Society
► Inequality

► Community

► The Individual
► Identity, morality & ethics

► Human connection
Top 10 Skills to be relevant in Industry 4.0
Thank YOU