Industry 4.0 for Manufacturing – A Paradigm Shift
The Fourth Industrial Revolution, or Industry 4.0, is the transformation cycle that changes the way manufacturers use technology to rapidly improve the manufacturing and distribution of goods. Where Industry 3.0 brought computerization to manufacturing, Industry 4.0 enhances and optimizes the computerization of the supply chain.
Manufacturers are looking to use digital data to identify efficiencies and deficiencies across the supply chain by incorporating digital technologies, such as AI and machine learning, Internet of Things (IoT) devices, and cloud and cognitive computing, and advanced analytics. These “smart factories” are using the technology as a paradigm shift to innovate and evolve supply chains to become smarter, execute faster, with velocity, and scale to the demand, on demand.
Industry 4.0 engages digital technologies to tighten the processes across an organization that supports the supply chain, through internal processes and business partners, and key external business partners in the value chain. The digitization of data will help manufacturers refine products and services in (near) real time and quickly adjust to the customer’s needs and wants.
Key Technologies Driving Industry 4.0
- Internet of Things (IoT) are physical sensors that capture inputs and outputs to connect and exchange data with other devices and systems. For example, a smoke detector can connect with your HVAC controller, so when a smoke alarm is triggered, it automatically shuts off the HVAC system to help minimize damage.
- Cyber-Physical Systems (CPS) is a computer system that monitors and controls a network of interacting elements by using sensors and robotics to obtain inputs and outputs. An example of CPS is how sensors read traffic patterns on highways then instruct on-ramp traffic lights to accelerate or slow incoming traffic to the roadway.
- Cloud Computing is where digital data is stored and analyzed. Cloud computing eliminates the need for physical servers and allows manufacturers to scale their computing needs, up or down, on demand.
- Cognitive Computing refers to a broad set of hardware and software technologies that mimic human systems (sensory, memory, analytical). Technologies include Artificial Intelligence (AI), Machine Learning, Natural Language Processing (NLP), reasoning, speech recognition, and visual object recognition. Predictive maintenance is one of the biggest opportunities that came from cognitive computing, which keeps the manufacturing lines open with less unexpected down time.
- 3D Printing has enabled manufacturers the flexibility to create products on demand, which reduces warehouse costs and allows for customized products. Manufacturers can also create their own spare parts locally, which improves supply chain up time and reduces dependence on 3rd party support service providers.
- Data Analytics is the transformation of raw data into actionable insights and trends. After large amounts of data are captured from sensors and connected devices into data lakes and data warehouses, visualization and analysis tools are applied to help manufacturers improve the speed and accuracy of their decision making.
Advantages of a smart (Industry 4.0) manufacturing approach
- Improved customer satisfaction: Smart Industry 4.0 manufacturing provides decision-makers with access to (near) real-time accurate data, which supplies leaders with the ability to measure and assess key performance indicators (KPIs) to adjust and adapt to trends that align with customer needs, in real time.
- Increased quality: Adding digital technology to manufacturing expands the data analysis of process inputs, outputs, and execution to reduce the chance of human error and failure. Digital data allows manufacturers to monitor process and performance in real time, to increase output and use resources more efficiently.
- Lower operational costs with predictive maintenance: Smart factories use digital data to predict, identify, and resolve maintenance issues efficiently and faster, which reduces expensive equipment repairs and avoid disruptions to production.
- Significant cost reductions: Immediate access to supply chain and production data for analytics and analysis increases predictive and forecasting accuracy, which helps to reduce waste and costs through tightly managed demand management.
- Enhanced productivity: Digital data generated from autonomous machines communicating with each other enables real-time insights into manufacturing processes, which helps managers adjust efficiency planning to enhance productivity.
- Improved employee satisfaction: Access to modern technology attracts and retains talent. Modern technology also reduces human error, which means employees have fewer dissatisfied customers to engage.
- Energy efficiency: Manufacturers can reduce their carbon footprint by reducing manufacturing and processing waste. More efficient manufacturing can reduce energy waste which can help make products more affordable as a result.
How Vigilant helps our manufacturing clients become a Smart Factory
|The Internet of Things (IoT)
|Oracle Fusion Cloud IoT Intelligent Applications
Predict maintenance needs and prevent unplanned downtime. Detect, analyze, and respond to IoT signals in factory settings. Enable real-time visibility of asset health, location, and utilization.
|Oracle Fusion Cloud Manufacturing
Streamline your global, mixed-mode manufacturing to make anything, anywhere, with an intelligent, optimized, and integrated solution powered by IoT and AI.
|Oracle Fusion Cloud Maintenance
Transform your maintenance processes with an integrated and intelligent enterprise asset management system that’s written for the cloud and designed for the Internet of Things environment. Use Industry 4.0 capabilities and predictive analytics to predict asset failure, estimate reliable lifespan, and trigger prescriptive workflows to take preemptive action.
|Oracle Fusion Cloud Quality Management
Drive closed-loop quality processes through design, procurement, inventory, manufacturing, and field service to ensure rapid detection and resolution of quality events. Make faster, more informed decisions and reduce risk with a predictive and connected 360-degree view of product quality across product lifecycle and supply chain processes.
|Supply Chain Planning
|Oracle Fusion Cloud Supply Chain Planning
Get better results faster by planning your supply chain end-to-end in the cloud. Effortlessly combine demand insights, supply constraints, and stakeholder input, and apply built-in machine learning to improve profitability while accelerating customer service.
|Oracle Analytics Cloud
Address the entire analytics process, from data ingestion and modeling, through data preparation and enrichment, to visualization and collaboration, without compromising security and governance. Use embedded machine learning and natural language processing technologies to help increase productivity and build an analytics-driven culture in your organization.
|Data Lakes / Data Warehouse
|Oracle Cloud Infrastructure (OCI) / Oracle Database
Large amounts of real-time data are generated by embedded sensors and connected equipment. These are best stored in a data lake, a storage architecture designed to store raw and structured data. Another data storage architecture called a data warehouse combines data from multiple sources, including the data lake, that enables data visualizations and analysis for better decision-making.
|Oracle Integration Cloud (OIC)
Connecting systems, devices, and databases are critical to smart Industry 4.0 manufacturing. With many pre-built connectors, Oracle Integration Cloud offers speed and simplicity to connecting your core manufacturing systems for real-time actionable data.
|Oracle Fusion ERP and SCM, including Manufacturing and PLM
Having the right applications to support the supply chain, order management, manufacturing, and accounting are critical for capturing the key process inputs and outputs to operate your business efficiently and effectively. Vigilant uses only certified and experienced consultants to help you implement, configure, and optimize your Oracle application environment to ensure you maximize the ROI while running your smart Industry 4.0 manufacturing business.
|Robotic Process Automation (RPA)
Business processes that are easily defined, repetitive, manual, and do not have a lot of variability in the process execution can all be automated using Robotic Process Automation tools. Vigilant uses certified RPA experts that assess your technology landscape and provide you with an expertly crafted automated solution. Automating the lower value manual data entry tasks enables your employees to focus on higher value tasks.
Industry 4.0 is how manufacturing plans are leveraging technology to create smart manufacturing environments that can identify, detect, and predict issues and opportunities to create efficient supply chain and production execution, which keep costs low, customers satisfied, and employees happy. Vigilant helps our customers engage today’s digital technologies to achieve the benefits attributed with smart manufacturing.