Workshop on IR 4.0 in India

In IR 3.0, computerisation and automation were considered important aids in improving productivity, and were given an enormous thrust. In IR 4.0, every process, machine and activity is broken down to the basic granular level and treated as a data point. Various measurement metrics are monitored for these data points to help in data-driven decision-making.

IR 4.0 is an ongoing process, with connectivity being the key. A business in this context must establish connection protocols for every machine in their ecosystem with the corporate network, which is fast and secure. Organisations must establish a clear cut plan of action with timelines to establish connectivity. As a next phase, a rigid signal capture and data storage system must be put in place. Data-driven decision-making models and protocols that can provide automated feedback to the system must be established. Training and sensitisation of employees towards the principles of IR 4.0, and software and hardware upgrades to meet the requirements of IR 4.0 connectivity are also important factors.

It enables easy backend integration with ERP/MES etc. It allows for various micro-services and the distribution of various functionalities to different nodes. 4.0 also makes resource management easy with transparent and monitored communication pathways. It is easy in this environment to add new protocols and processes as an additive measure. It is also possible to establish communications among various components and profit centres on the shop floor.

Lean manufacturing is an ongoing process of identifying wasteful practices, reducing costs and improving quality. Under the IR 4.0 paradigm, the focus is on connections among the various assets and nodes in an organisation. IR 4.0 architecture will eventually help achieve the goal of Lean.

Some of the key concerns that need to be addressed before moving to an IR 4.0 architecture are cyber security, handling an enormous volume of data, resource training and deployment, and very long ROI cycles that may lead to the company’s management pulling the plug midway.

The Internet of Things (IoT) is a term that stands for the connections of processes, people, data and devices over an IT network. IoT enables the connectivity of machines and equipment on the factory floor. It is an important component of Industry 4.0.

The Industrial Internet of Things (IIoT) is a term that stands for the Internet of Things (IoT) in an industrial environment. IIoT solutions are part of cyber-physical technologies that define the fourth Industrial Revolution. It encompasses additional solutions such as Additive Manufacturing, Digitisation of Business Processes and Advanced Control Systems.

Industry 4.0 solutions improve the efficiency, quality and utilisation of factory operations. Businesses across geographies have shown improved factory productivity and product quality, and reduced operating costs after adopting Industry 4.0 solutions. Simply put, Industry 4.0 helps manufacturers make more in less time, and with fewer resources.