Principles of Industry 4.0 and the 9 Pillars

Dave Burrel - Senior Consultant, Product Design

By: David Burrell
Senior Consultant, Project Design

7th February 2019

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Industry 4.0 (i4.0) refers to the exciting area of automation within manufacturing including IOT, robotics, cloud computing and data management. We can look to the not-very-distant future and see robotics, sensors and integrated systems playing a huge part of a normal manufacturing process. With technologists and engineers regularly discussing topics like the “Smart Factory” and the “4th Industrial Revolution”, David Burrell, Senior Consultant of our Manufacturing Services, discusses what Plextek has been up to in this arena:

“It is interesting to see all the excitement around i4.0 and how we should all be getting involved. But in the end you have to ask yourself, what does it really mean and surely we have been doing this kind of thing for years? In reality, i4.0 is largely the repackaging and combination of capabilities and technologies that already exist; but providing the overall wrapper that enables total interoperability, collecting Big Data, manipulating it and then applying it as positive feedback to improve functionality and efficiency.

“If we look at the 9 pillars of Industry 4.0 below, I have assigned examples to each pillar to show how existing systems, technologies and ideas can be applied to the Industry 4.0 framework:

  1. IOT: IOT gives us the ability to realise Smart Cities: for example, we developed and implemented an intelligent street lighting system and network which can now be enhanced to incorporate collation of environmental data and additional video links.
  2. Big Data: Within the field of vehicle tracking, companies can now manage and interpret Insurance data to enable the interpretation of driver behaviour and accidents.
  3. Cloud Computing: Harvesting large quantities of data involves careful management, and providing a ‘Data warehouse’ facility to organisations is invaluable.
  4. Advanced Simulation: Complex algorithms and testing them allows for projects like inner-city intelligent parking or a ‘Dead reckoning’ capability for GPS denied environments to come to fruition.
  5. Autonomous systems: More systems in business are becoming autonomous and need less human intervention to provide effective results.  We’ve applied this to a transport scenario, with an interesting project recently completed around object and vehicle detection.
  6. Universal Integration: Integrating Factory Test equipment and a bespoke Manufacturing Execution System can enable remote access and feedback into product test yield, improving projections.
  7. Augmented Reality: By creating computer-generated perceptual information it is becoming easier to train your staff, even in unique and difficult conditions. It is very hard for example to provide training scenarios for humanitarian crisis aid or battlefield healthcare without risky in-field training unless you consider AR.
  8. Additive Manufacture: Application of AM techniques to achieve fast market entry and creative solutions is becoming more important in a competitive environment. I have previously written a blog on the 4 steps of Additive Manufacture.
  9. Cyber Security: Security of your infrastructure, both online and offline is a business critical factor. Bespoke systems design will ensure your organisations’ Data Integrity

Having all of these capabilities is all well and good but that is just the beginning, they need to be applied to something in an interconnected way within the manufacturing environment to be counted as Industry 4.0, but that is only an application specific criteria. Industry 4.0 is an exciting area as innovation is combined with sustainable processes.”

For an initial chat about Industry 4.0 and how we can help future-proof your business, then get in touch.

Industry 4.0 (i4.0) refers to the exciting area of automation within manufacturing including IOT, robotics, cloud computing and data management. We can look to the not-very-distant future and see robotics, sensors and integrated systems playing a huge part of a normal manufacturing process. With technologists and engineers regularly discussing topics like the “Smart Factory” and the “4th Industrial Revolution”, David Burrell, Senior Consultant of our Manufacturing Services, discusses what Plextek has been up to in this arena:

“It is interesting to see all the excitement around i4.0 and how we should all be getting involved. But in the end you have to ask yourself, what does it really mean and surely we have been doing this kind of thing for years? In reality, i4.0 is largely the repackaging and combination of capabilities and technologies that already exist; but providing the overall wrapper that enables total interoperability, collecting Big Data, manipulating it and then applying it as positive feedback to improve functionality and efficiency.

“If we look at the 9 pillars of Industry 4.0 below, I have assigned examples to each pillar to show how existing systems, technologies and ideas can be applied to the Industry 4.0 framework:

  1. IOT: IOT gives us the ability to realise Smart Cities: for example, we developed and implemented an intelligent street lighting system and network which can now be enhanced to incorporate collation of environmental data and additional video links.
  2. Big Data: Within the field of vehicle tracking, companies can now manage and interpret Insurance data to enable the interpretation of driver behaviour and accidents.
  3. Cloud Computing: Harvesting large quantities of data involves careful management, and providing a ‘Data warehouse’ facility to organisations is invaluable.
  4. Advanced Simulation: Complex algorithms and testing them allows for projects like inner-city intelligent parking or a ‘Dead reckoning’ capability for GPS denied environments to come to fruition.
  5. Autonomous systems: More systems in business are becoming autonomous and need less human intervention to provide effective results.  We’ve applied this to a transport scenario, with an interesting project recently completed around object and vehicle detection.
  6. Universal Integration: Integrating Factory Test equipment and a bespoke Manufacturing Execution System can enable remote access and feedback into product test yield, improving projections.
  7. Augmented Reality: By creating computer-generated perceptual information it is becoming easier to train your staff, even in unique and difficult conditions. It is very hard for example to provide training scenarios for humanitarian crisis aid or battlefield healthcare without risky in-field training unless you consider AR.
  8. Additive Manufacture: Application of AM techniques to achieve fast market entry and creative solutions is becoming more important in a competitive environment. I have previously written a blog on the 4 steps of Additive Manufacture.
  9. Cyber Security: Security of your infrastructure, both online and offline is a business critical factor. Bespoke systems design will ensure your organisations’ Data Integrity

Having all of these capabilities is all well and good but that is just the beginning, they need to be applied to something in an interconnected way within the manufacturing environment to be counted as being Industry 4.0, but that is only an application specific criteria.

Industry 4.0 is an exciting area as innovation is combined with sustainable processes.  For an initial chat about Industry 4.0 and how we can help future-proof your business, then get in touch.

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