The manufacturing execution systems level

We have already begun moving away from conventional monolithic record systems in manufacturing systems, but here a lot is ready to change.

Think artificial intelligence and machine learning, increased autonomy, the transition to a servicing-orientated and flexible service approach previously stated, more integrations with far more systems than is already the case and MES works with embedded systems with a much more end-to-end approach beyond the floor and also let alone the individual plant.

The Complicated Levels of SCADA Systems

Lastly, SCADA is there. SCADA systems continue to be an essential step in operability and as usual, to generate successful intelligence are seen as crucial for the relation of distributed properties.

Although Industrial IoT and SCADA are agreed in the short to medium run to remain, or to become good friends, as SCADA is required in a variety of situations today, defense, intelligence, and functionality are likely to disappear in the longer term in ERP, PLC and IoT are only increasing at all levels.

SCADA has very few arguments that remain important in the overall range of IoT and technological developments in the long term. But tomorrow isn’t it. Particularly, the first shift will be HMI/SCADA and the entire HMI layer, as comprehensive modern technology offers a wide variety of new interface experience for human-machine applications.

There is however a long way to go, not least in the area of SCADA/HMI defense, and at all the other levels listed.

The “human system” Decides it all in the End

Industry 4.0’s priorities are very evident. There’s another game of ball getting there. Perhaps we can never get there absolutely, nobody’s got a crystal ball.

However, for others, paper always gets rid of in the meantime and for some it catches up, for some, it shifts to creativity and what it all is about in the final analysis: the real results which are human by definition. Furthermore, if all the drastic changes described in software and systems, in processes and ways to simplify, automate, create value and transform experiences will be fully implemented, is ultimately also an issue of humankind.

And here’s the simple thing: it’s not the intelligence that’s working or the link of actionable intelligence with far more links and various bits of intelligence that counts too.

Industry 4.0 Evolutions Around The World and Initiatives

The view of Industry 4.0 has clearly become global and still does, as was described in the introduction to our article, as well as the scope of the reference architecture model for Industry 4.0 for RAMI 4.0.

In the USA, Industry 4.0 has a major effect on intelligent manufacturing initiatives, and cooperation is being formed with the Industrial Internet Consortium.

In addition, a growing number of businesses and countries are implementing Industry 4.0. Some examples include Great Britain (in Industry 4.0 and workaround 4IR), Japan (where collaboration with Japan’s Robotic Revolution Initiative has already been pointed out), China (where the outline of Industry 4.0 is based on ‘Made in China 2025’), and a large number of EU initiatives, some of which we have referred earlier. On 23 Mark 2017 alone, the EU examined proposals to coordinate the current twelve and nine upcoming measures for national industrial processing. Moreover, all of them use the Industry 4.0 definition, irrespective of their various titles.

However, Industry 4.0’s global expansion is not just a question of government policies or agreements. The emphasis on business giants and leading industry 4.0 consultancy firms is also growing.

They are both deeply interested in Industrie 4.0, from PwC and Accenture to McKinsey. One example of a non-EU giant heavily involved in Industry 4.0 is Infosys who sponsored the plans for the Industry 4,0 Maturity Index of the German Academy of Sciences and Engineering, acatech (coined by Industry 4.0).

In the Spring of 2016, the consortium was formed to complete the Industry 4.0 Maturity Index by April 2017 and includes academic institutions and also many industry organizations as well as firms such as Infosys.

Wait for a number of announcements and collaborations to propel the Industry 4.0 concept worldwide. Last but not least, note that we are not only seeing a global/regional expansion of Industry 4.0. Moreover, Industry 4.0 is gradually being introduced in vertical industries, outside the manufacturing sector (healthcare, utilities, smart cities, oil, and gas, etc.).

Industrial Data Space: Smart Services in Industry 4.0 and Linking IoT and Beyond

A number of research institutions leading the Fraunhofer Institute and the German Government push for a model of the reference architecture and virtual structure to secure data sharing on the basis of structured communication interfaces.

Furthermore, this is a bumper to suggest that industrial data space, intended to describe the infrastructure for the interaction of intelligent services and IoT in an increasingly data-based environment, wants to become a global standard. In order to allow partners to share their data for digital transformation purposes, Industrial data space focuses on the link between several existing systems within a clearly predefined model in which data sovereignty and data protection are among the core areas of emphasis.

The Industrial Data Space Association conducts talks within the scope of the European data space movement with other organizations with similar structures, countries outside Germany and the EU. While industry 4.0 is a big focus, the industrial data space also applies to other industries. Moreover, the diagram below illustrates some of the key concepts of the Industrial Data Space, provided by Prof. Dr. Jan Jürjens on the EU website (which can be viewed here in pdf).

FAQ About Industry 4.0

What is Industrie 4.0 / Smart Manufacturing/ Industry 4.0?

The phrase “a paradigm shift, made possible by technological advances, which constitute a reversal of conventional production process logic” says GTAI (German Trade and Investment Association) about Industry 4.0. Germany’s response to globalization is known also like the Smart Manufacturing and Industrial Internet of Things – IIoT. In addition, the goal is to enable companies to achieve unprecedented levels of performance and effectiveness, especially in the manufacturing and engineering sectors. For this purpose, versatile technologies are used to digitize and integrate:

Horizontal & Vertical Value Chains

Services & Product

Customer support & Business Processes

How does Industry 4.0 vary from Lean manufacturing?

Lean production is one process developed in Japan at the end of 1980. Lean production or lean production. Besides, it is a philosophy of industry that uses continuous structural models to reduce waste to a minimum and to optimize the use of resources.

The next stage of efficiency is Industry 4.0. In its emphasis on end-to-end digitization, it links digital environments with value chain partners and incorporates them using cyber physics systems. This vast network of emerging technology and knowledge exchange in real time between men and systems provides businesses with unmatched levels of success, productivity, and also quality.

What are Cyber-Physical Systems?

Enterprise Management Solution (EMS) systems allow companies to Cyber-Physical Systems:

The next chapter on industrial growth is Cyber-Physical Systems (CPS). These systems allow technologies to combine computers and networks with physical processes in the virtual world to create an environment that allows “intelligent” objects to talk and react.

Operations, procedures, and also planning are transparent,
Ease of implementation, link, service, and maintenance of equipment,
Interoperability through the limitless integration of whole operations horizontally and also vertically,
Instant results, which means the best data quality.

EMS systems exchange data in real-time through interconnected networks such as sensors, interfaces, software systems, and actuators for physical processes via intelligent interconnections with all existing systems, devices, locations, etc. This allows businesses to exchange high-quality data in various locations and business units with the information submitted immediately.

This latest systems generation:

If the plant is not shut down, no data or output distortion occurs,
Can be run as an established stand-along or part of an IT infrastructure,
Are totally adaptable, intuitive, and need limited preparation and supervision. Are fully adaptable.

How does Industry 4.0 vary from the Internet of Things (IoT)?

Industry 4.0 and the Internet of Things have also very similar concepts, particularly the networking of a variety of “things” so that they can speak and react proactively without human intervention.

The key distinction is however that IoT focuses largely on the connection of daily consumer projects, while Industry 4.0 focuses more on production processes that produce smart plants and lead to intelligent product creation.

How does your business profit from Industry 4.0?

Smart production facilities are produced by integrating the digital world with that of industrial production. Innovation, higher sales, market shares, and profits are powered primarily by far more efficient, consistent efficiency and also in industry 4.0 solutions. The capacity to produce in a cost-efficient manner, complicated configuration-to-order goods at a mass scale is just one of the advantages of Industry 4.0. The networked manufacturing equipment of these smart plants would automatically be able to diagnose itself before the production downtimes are repaired.

Early adopters praise to leap to Industry 4.0 for their bravery. Those who avoid this transition are in danger of being obsolete and abandoned.

How can Industry 4.0 contribute to value innovation?

The strategic logic of high growth is value innovation. The company uses the process to implement new technology or enhancements intended to distinguish between goods and services at low prices. Additionally, new data and new settings and the potential to restructure conventional business functions of intelligent connected goods.

Industry 4.0, by reducing or increasing some elements of the organization, helps businesses achieve value innovation. Following are some of the reductions and rises.

Reductions

Complexity

More setup and fewer programming
Method solutions simplification
Low value advising freedom
Multi-lingual flexible interpreter

Costs

No license for the customer (some cases)
Short and effective time to incorporate
Performance of maximum capital
Elimination of the cost driver due to actual data use
Reduced training essential (intuitive user guidance)
Low maintenance of the machine
Access to Leasing Model (some cases)

Risks

Flexible application of the framework (step by step)
Installing and upgrading during production
The decision on actual, immediate knowledge

Waste

Reduction of scrap, leading to the removal
Maximizing the use of electricity
Managers relieve from tasks related to administration

Dependency

Device Client Controlled – Set to customer requirements
External consultant for the development of added value

Vagueness

Operational transparency 100%
Application of actual words
Routines of the learning system

Increases

Simplicity

Intuitive windows as a user interface framework
Standardized device integration and data transfer
System training, use of existing resources, also personnel

Convenience

Instant global access to all data generated,
Integration of various metrics

Interconnectivity

Complete transparency among alternative business processes, different locations, software solutions, and machinery departments also, etc.
Capacity for holistic factory management
The Mobile App

Flexibility

Settings and customization of the interface
All technical equipment accessibility
Customer Usability 100 percent solution
Capacity for simulation and prediction

Productivity

Vertical and Horizontal Convergence
The first day of introduction
Traceability and openness

People Empowerment

Simplifying training
Production of value tasks (New Business Processes, solutions, etc.)
Comparison of various metrics
Forecast and simulations
Communication at multi-level

How will Industry 4.0 be implemented?

While connectivity is the key to the creation of data, the right tools do not guarantee a successful transition to industry 4.0. The best solution is a systematic approach. Furthermore, Below are a couple of measures to effectively introduce Industry 4.0.

Identify your major problem and launch a small scale

In stages, Industry 4.0 can apply and must not finish all at once. Multiple stakeholders and phase gates include as a process. Concentrate on what is the company’s most critical challenge. Besides, it allows you to consider the benefits and problems of the implementation of emerging technology on a scale. You can also achieve a quick ROI while helping your people to customize to the new empowerment instruments that they have.

Following a method of change management

Industry 4.0 is a paradigm shift That involves the management of the transition. It needs comprehensive cooperation between employees and leaders. Training and communication are of vital importance. Based on the prejudices they have regarding Industry 4.0 you want to sabotage the efforts. In addition, orporate culture is a central element in Industry 4.0’s success or failure. The management must consider the obvious advantages, but also the possible pitfalls of an intelligent future farm. It must become part of the culture of Industry 4.0 to ensure full buy-in from day one. Also, it has to be an integral part of decision making.

Enter a direct link between operational technology (OT) and IT (IT).

This is crucial for your investment to capitalise. Different software employed by most businesses. Building on acquisitions and mergers can also lead to multiple software solutions that have difficulties communicating with others kor require human input for data transfer between different sources. Moreover, if the new platform is not included in the OT, your investment will have little impact on your operations. Link the IT to OT during conversations, seminars, and also workshops to make sure that it is the shared task of transferring the business towards industry 4.0. For a smooth transition, both sides need support and commitment.

Select the best solution for apps

There is a saying, “When nothing changes, nothing changes.” Added advantages for both products and services are a new type of software solutions (SCPs). The market provides various solutions but finding the right solution can lead to long decision times and many complications. Current IT solutions (ERP, MES, business owners, etc.) and existing operating equipmentmust also take into account. The importance of EMS systems, which empower companies with unprecedented interconnectedness, is important here for interoperability and also real-time data. Undoubtedly, o licensing model, versatile methods of payment, zero downtime are essential things that Smart software solutions may deliver.

My advice; look for ways to suit your business needs. Try and readjust the pilot option. You will benefit directly, but also obviously from a pilot program. Consider the time, costs, and support for installation and adjustment. The manner in which decisions about the correct CPS/EMS software are made is critical to be noted. Besides many of the software solutions that exist are too static, too complicated and costly, and very late in ROI. Many businesses have chosen that because of protection. Also choosing an employee’s “Safe” option might not be the best choice for the whole company’s long-term strategy and development. Furthermore, Additional advantages can result from differentiation.

Focus on your company’s next needs after the first win

Identify the next needs and specifications immediately. The best choice could be modular intelligent software solutions. These systems may substitute a single interoperable, enterprise-wide system for obsolete legacy systems such as those for operations management and also corporate resource planning.