What Is Industry 4.0?
Industry 4.0 Definition: Industry 4.0 refers to the intelligent networking of machines and processes in a production facility using information and communication technologies. The fourth industrial revolution is characterised by the digitalisation of all production processes. What does that mean, you ask? In short, manual production processes are optimised with the help of modern technologies to enable networking and self-regulation.
The interaction between people and Industry 4.0 tools has many advantages for companies: Employees can continue to contribute their individuality and creativity, while networked machines collect and analyse data in real-time and make it available to the company.
Modern Technologies Enable Communication
With the help of modern technologies, machines communicate with each other, exchange data and make automated adjustments. This networking makes it possible to make production processes more flexible, efficient and customised. This includes real-time data collection and reporting, which enables a rapid response to changes and thus creates the opportunity to continuously improve production processes.
Industry 4.0 technologies include the Industrial Internet of Things (IIoT), cloud computing, artificial intelligence (AI) and big data. An MES (Manufacturing Execution System) is an important key element in the digitalisation of production. With an MES, machine and operating data can be digitally collected in a company for the purpose of optimising production. This provides a digital image of production and enables real-time monitoring of production processes.
Industry 4.0 With New Possibilities
We are pleased to present our new event series FASTEC ON-SITE!
In this practical series of events, you will experience our FASTEC 4 PRO software live in our customers’ production facilities. The focus is on digitalised production processes with our MES solution.
Experience how our customers use FASTEC 4 PRO to optimise their production:
Exclusive insights into a wide range of industries
Real implementation examples of the modular FASTEC 4 PRO software
Practice-orientated production tours
Best practices from our customers, keynote speeches, key speakers and personal experience reports
Professional platform for professional exchange and diverse networking
The event series is primarily aimed at customers, interested parties and partners of FASTEC GmbH and the organising company. The number of participants is limited.
Curious? You can find more detailed information on the individual events at staging-fastecde.temp312.kinsta.cloud/on-site
For your company, Industry 4.0 means increased efficiency, more flexibility and optimisation of production processes through real-time data and analyses. The digitalisation of production involves close collaboration between man and machine. Assistance systems support people in their daily work. Industry 4.0 is playing a pioneering role in Germany, where research, development and application are particularly closely interlinked. The aim of this is to strengthen the competitiveness of industry.
Before the fourth industrial revolution began, there were three other key developments, which are explained in the following section. In each revolution, relevant innovations optimised manufacturing processes. The way products were manufactured and the way people worked in factories changed time and again.
What Is The Difference Between Industry 1.0 and Industry 4.0?
Industry 4.0 represents the fourth industrial revolution and builds on its predecessors. Industry 1.0 began with mechanisation using water power and steam engines. Industry 2.0 brought mass production through assembly line labour and electricity. Industry 3.0 brought automation through computers and robotics. Finally, Industry 4.0 stands for the digital transformation of industry, in which the Internet of Things (IoT), big data and artificial intelligence (AI) play a central role.
As the definition of Industry 4.0 also includes the history of its development, we will take a closer look at the transformation below. If you would like to find out more about the technologies directly, simply scroll down a little further.
Industry 1.0
Industry 1.0 marks the transition from traditional craftsmanship to mechanised production. This change began in the 18th century with the introduction of mechanical production facilities driven by water and steam power. Steam power had been known for some time, but its introduction into industry was a major breakthrough. The textile industry played a pioneering role, as looms and spinning machines significantly increased productivity. With this first industrial revolution, factories emerged and the way people worked and lived changed fundamentally.
Industry 2.0
Industry 2.0 marked the beginning of mass production. Compared to Industry 1.0, which was characterised by the introduction of mechanical production facilities with water and steam power, Industry 2.0 enabled an enormous increase in productivity. Assembly line work and the use of electrical energy in the 19th century significantly changed industrial production. Mass production began with the American inventor and automotive pioneer Henry Ford (1863-1947), who observed the production methods of a slaughterhouse in Chicago and transferred them to the automotive industry. The aim was to break down the production process into sub-steps. Previously, companies had assembled an entire vehicle at one station. Ford eventually introduced production on the assembly line in stages. This change resulted in far-reaching social and economic changes and laid the foundation for further industrial developments.
Industry 3.0
The third industrial revolution characterises the transition from mechanical to digital technology. At the heart of Industry 3.0 is the introduction of computers and automation in production processes in the 20th century. Thanks to these technologies, it is possible to automate an entire work process. This also includes robots, which replace humans. While these were initially simple machines that took on individual tasks, they quickly developed into complex systems that automated entire production chains.
Industry 4.0
We are currently in the midst of Industry 4.0, which aims to digitally network all industrial components in a production facility. The term itself was first introduced at the Hannover Messe trade fair in 2011 and has since become increasingly important worldwide. The key difference to the previous industrial revolutions lies in networking and therefore digitalisation.
The industrial development from Industry 1.0 to Industry 4.0 shows a continuous progress: While Industry 1.0 introduced mechanisation through water power and steam power, Industry 2.0 brought mass production through assembly line work and electrical energy. Industry 3.0 ushered in the era of automation, in which robots and computers increased efficiency enormously. Industry 4.0 finally enabled the use of intelligent information and communication technologies.
Which New Technologies Are Shaping Industry 4.0?
Industry 4.0 makes use of a wide range of technologies. Many companies, perhaps even yours, use some of these innovations individually. However, companies can only exploit the full potential of Industry 4.0 if they use several tools together. The technologies create a connection between man and machine as well as between the systems themselves. This results in intelligent and autonomous systems.
The technologies within Industry 4.0 include:
- Sensor technology to capture and process precise data in real-time
- Artificial intelligence (AI) to imitate human capabilities
- Communication technologies for the exchange of data
- IoT and IIoT for the intelligent control and monitoring of processes
- Big data for real-time data analysis and reporting
- Cloud computing for accessing data and applications via the internet
- Digital twins for simulating states and behavior
- 3D printing for the construction of prototypes, complex components and series production
- MES for machine and production data acquisition to optimize production
What Are The Benefits Of SensorTechnology?
Sensor technology as a central component of Industry 4.0 enables the collection and processing of precise data in real-time. The result is improved monitoring and control of machines and systems. By using sensors, production processes can be optimized, resources can be used more efficiently and Planned maintenance can be designed preventively. The sensor data forms the basis for automation and networking in the smart factory, leading to increased productivity and flexibility. Ultimately, sensor technology promotes the development of new business models and offers companies a significant competitive advantage in the digitalized industry.
What Is Artificial Intelligence (AI)?
Machines with artificial intelligence (AI) can imitate human abilities such as logical thinking, learning, planning and creativity. They do this by recognizing and sorting information from input data. AI can be based on programmed processes or generated by machine learning. This makes it a branch of computer science.
AI enables technical systems to perceive their environment, deal with it and solve problems in order to achieve a specific goal. A computer receives data, processes it and reacts. AI systems can adapt their actions by analyzing the consequences of previous actions and working autonomously.
What Communication Technologies Are Available?
Industry 4.0 is revolutionizing the way factories communicate and function. Modern communication technologies are the basis of this fourth industrial revolution. One key element is the Internet of Things (IoT). It networks devices and machines so that they can exchange data with each other. Wireless technologies such as Wi-Fi, 5G and Bluetooth also play a central role by providing fast and flexible connections. Cloud computing makes it possible to store and process large volumes of data. Big data analytics supports the analysis of this data to increase efficiency and productivity. Cyber-physical systems (CPS) form the interface between the physical and digital worlds and ensure that physical processes are controlled digitally. Together, these technologies enable seamless communication and integration across the entire production chain.
What Are The Internet Of Things (IoT) And The Industrial Internet Of Things (IIoT)?
The Internet of Things (IoT) refers to the networking of physical and virtual objects that can communicate and interact via the internet. The aim is to enable intelligent control and monitoring of processes. Devices are equipped with sensors and collect data, which is then exchanged via the network. This enables them to react independently to information and carry out actions.
The Industrial Internet of Things (IIoT) refers to production and manufacturing. In some cases, this term is equated with Industry 4.0. The Industrial Internet of Things monitors and controls functions in production. This can be done both on site and remotely. IIoT forms the basis for networking within industrial production and allows manufacturing processes to be optimized and automated. Data can be collected, processed and reported in real-time. Vehicles, containers, crates or pallets are equipped with automatic identification chains to ensure the transparency of an entire supply chain. A GPS-enabled connection via the IIoT enables current positions to be displayed and routes to be tracked.
What Does Big Data Mean?
Big data refers to extremely large volumes of data that are diverse and very fast. This data is so extensive and complex that it cannot be processed using conventional data processing tools. Big data plays a crucial role in Industry 4.0, as real-time data analysis and reporting is used to optimize production processes and decision-making. With advanced technologies such as artificial intelligence (AI) and machine learning, companies gain valuable insights from big data and can thus operate more efficiently and competitively.
What Is Cloud Computing?
Cloud computing is also a component of Industry 4.0 and is a key technology. It allows companies to make data and applications accessible via the internet instead of storing them on local computers or servers. This technology offers flexibility, scalability and cost efficiency, as resources are used and adapted as required. In Industry 4.0, cloud computing enables a networked data infrastructure that allows machines and systems to be operated, maintained and monitored more efficiently. This enables companies to optimize their production processes and drive innovation faster.
How Do Digital Twins Work?
Digital twins are virtual images of physical objects or systems. They work by collecting and using real-time data from sensors and other sources of information from their physical counterparts. This data is analyzed and processed in a virtual model that simulates the states and behavior of the real object. This enables companies to optimize processes, predict problems and plan Planned maintenance more efficiently. By constantly updating it with new data, the digital twin always remains up to date and becomes a key tool for Industry 4.0.
What Is 3D Printing?
3D printing is also a component of Industry 4.0. A 3D printer produces three-dimensional objects. In contrast to a conventional 2D printer, a layer of paint is not printed onto an object, but an entire object. 3D printing is a manufacturing process that builds three-dimensional objects layer by layer from materials such as plastic, metal or ceramic. The digital model of the object is first created on the computer and then transferred to the 3D printer, which converts it into physical form. This is done by adding layers of material that are placed precisely on top of each other until the final product is ready. 3D printing is used for prototypes, complex components and increasingly also in series production. It offers the possibility of individualizing products and can save time and costs in the manufacturing process.
What Is An MES?
An MES (Manufacturing Execution System) is a production software for the manufacturing industry. It performs data acquisition tasks. It can be used to digitally collect machine and operating data in a company for the purpose of optimizing production. This includes information on throughput times, machine statuses, reasons for malfunctions and duration. The report of this data provides information about potential errors in the production process and opens up the possibility of detecting faults in real-time and making targeted optimizations in the long term. What used to be recorded manually on paper and in Excel files can now be recorded automatically – saving time for employees and increasing transparency throughout the company.
The aim of using an MES is to optimize production processes and improve manufacturing efficiency. By collecting and analyzing data in real-time, MES software enables the precise planning and control of production processes. By integrating with other systems such as an ERP (Enterprise Resource Planning), an MES helps to improve responsiveness to modifications in production. In short, MES software is the basis for efficient, modern production operations in the context of Industry 4.0. In addition to Plant and Machine Data Acquisition (MDA/PDA), an MES usually also has modules such as Maintenance, Traceability, Quality Assurance and Production Planning.
What Solutions Does An MES Offer For Industry 4.0?
The Industry 4.0 technologies described, primarily an MES, form the foundation for a smart factory. An MES is at the heart of the digital transformation in the manufacturing industry – making it an indispensable tool on the road to the factory of the future. It is the central platform for controlling production processes. With FASTEC’s MES, FASTEC 4 PRO, you can monitor and control your production plants, machines and workflows in real-time. You collect data directly from the production lines, enable precise planning and analysis of production processes and thus support decision-making in your company. By integrating MES software into production, also known as MES production, companies can maximize efficiency, reduce costs and improve product quality.
The MES FASTEC 4 PRO enables a continuous flow of information in your company. It works like this: The MES receives master data (resources) and transaction data (Production orders) from an Enterprise Resource Planning (ERP), which it processes into a worklist. It sends this to the machines on the store floor in production. Employees receive the planned orders at the terminals and start the machines. The MES automatically carries out Machine Data and Production data acquisition (MDA/PDA) to optimize production. It sends the collected data back to the ERP and makes it available to Controlling. The information is thus distributed throughout the company.
Digitalization Of Production With An MES Ensures Reliable Data
The use of an MES also simplifies the procurement of information in your company. Online monitoring allows employees to control production in real-time. This leads to prompt reactions to deviations and thus to an improvement in Overall Equipment Effectiveness (OEE), a key figure for evaluating the productivity of a plant. Comprehensive reporting with individual views enables quick decision-making in day-to-day business. Up-to-date, reliable data is available at any time at the touch of a button, allowing measures to be derived in meetings with production planning and scheduling. The digitalization of production also ensures reliable data.
Collecting data provides important insights into the potential of production. The implementation of measures ultimately optimizes production and leads to increased efficiency, less waste and higher output. Optimization of production through an MES is not only visible in figures, but also through greater transparency across departments throughout the company. Software solutions such as an MES provide a flexible and growing foundation for the digital factory.
Lars Knitter, Head of Sales & Marketing, Authorized Representative at FASTEC
If you decide to introduce an MES in your production, you should also implement a machine connection. This allows employees to see the progress of production live at any time on the terminal in FASTEC 4 PRO and receive the estimated order end date based on the remaining run time. The order changes its length dynamically, depending on the progress of production. This live feedback is also very helpful for the continuous flow of information described above. Production Planning has the flexibility to bring orders forward if something is finished earlier. They can also react in the event of a disruption and move an order back, for example. By binding the machines, the downtime is also displayed accurately.
How Can You Get Started With MES In Industry 4.0 Easily?
In addition to all the advantages of an MES, the introduction of this production software is extensive. FASTEC has developed smartOEE so that a potential analysis and thus the optimization of production is possible with minimal effort. It has a hybrid architecture consisting of cloud and edge and facilitates the entry into the digitalization of production with an MES. smartOEE is a “turnkey” system that companies can use directly after simple installation and activation (plug & play). This enables you to enter the digital factory quickly and cost-effectively. Production data is recorded digitally and can be reported directly in the cloud. By automatically calculating the Overall Equipment Effectiveness (OEE), companies can derive optimization measures and increase the productivity of their production. By using the cloud, the data is always available and can be used.
The edge components for smartOEE are provided by the FASTedge product family. The FASTedge Box creates the connections to the cloud, terminals and machines. It not only performs system control, but also guarantees fail-safe operation (always on). Production employees can use the FASTedge SFT15 touch terminal to make entries at the machine. Machine signals are recorded automatically and manually.
With the Industry 4.0 tool smartOEE, manufacturing companies can enter the world of MES with little effort.
Practical Examples Of The Use Of Industry 4.0
Some companies are already working successfully with FASTEC 4 PRO. The MES software supports the production process in terms of efficiency, quality assurance and data acquisition and analysis. Here you can find user reports from various FASTEC customers:
Conclusion
All in all, it can be said that Industry 4.0 offers many opportunities and potentials for companies. Industry 4.0 technologies enable a digitalized factory with optimized processes and increased output. Sensor technology enables precise data to be recorded and processed in real-time, artificial intelligence (AI) imitates human capabilities and an MES records machine and operating data to optimize production. An MES is considered to be at the heart of the digital transformation in the manufacturing industry. The report of the collected data provides information about potentials in the production process and opens up the possibility of detecting malfunctions in real-time and making targeted optimizations in the long term.
Do you have any further questions about Industry 4.0 and its implementation in your company? Then get in touch with us. We are happy to consult you!
