Industry 4.0 is bringing about the convergence of information technology (IT) and operational technology (OT) systems, creating interconnectivity between autonomous manufacturing equipment and broader computer systems. Then AI and machine learning are used to pull actionable insights from the large quantities of data.Ĭonvergence of IT and OT is a cornerstone of Industry 4.0 Smart factories employ IoT devices that connect machines and computers to get a clear picture of the manufacturing facility with real-time data. The digital transformation to Industry 4.0 starts with collecting data, then adds artificial intelligence to make sense of that data. After it is connected to a smartphone camera, the automated inspection model is ready to be added to the production line. Typically, the deep learning model can be quickly trained with existing images and videos. Read the Frost & Sullivan whitepaper on why Industry 4.0 mattersĪI visual insights lead to higher productivityĪugmenting manual inspections and technical assistance with AI-powered automated inspections cuts down on product defects, improving efficiency and minimizing false positives. By collecting more data from the factory floor and combining that with other enterprise operational data, a smart factory can achieve information transparency and better decisions. Flexibility is improved so that manufacturers can better meet customer demands using mass customization-ultimately seeking to achieve efficiency with, in many cases, a lot size of one. Characterized by increasing automation and the employment of smart machines and smart factories, informed data helps to produce goods more efficiently and productively across the value chain. We are now in the fourth industrial revolution, also referred to as Industry 4.0. ![]() ![]() The digitization of factories began by embedding programmable logic controllers (PLCs) into machinery to help automate some processes and collect and share data. The third industrial revolution, which began in the middle of the 20th century, added computers, advanced telecommunications and data analysis to manufacturing processes. These new power sources, along with more advanced communications via telephone and telegraph, brought mass production and some degree of automation to manufacturing processes. Second industrial revolutionĪ century later, the second industrial revolution introduced assembly lines and the use of oil, gas and electric power. Finished goods were built with machines rather than painstakingly produced by hand. Starting in the late 18th century in Britain, the first industrial revolution helped enable mass production by using water and steam power instead of purely human and animal power. Read the blog post about Industry 4.0 and manufacturing Industry 4.0 concepts and technologies can be applied across all types of industrial companies, including discrete and process manufacturing, as well as oil and gas, mining and other industrial segments. By applying machine learning algorithms, manufacturers can detect errors immediately, rather than at later stages when repair work is more expensive. With minimal investment, quality control personnel can set up a smartphone connected to the cloud to monitor manufacturing processes from virtually anywhere. Replacing manual inspection business models with AI-powered visual insights reduces manufacturing errors and saves money and time. Using high-tech IoT devices in smart factories leads to higher productivity and improved quality. ![]() Analyzing the large amounts of big data collected from sensors on the factory floor ensures real-time visibility of manufacturing assets and can provide tools for performing predictive maintenance in order to minimize equipment downtime. This digital technologies lead to increased automation, predictive maintenance, self-optimization of process improvements and, above all, a new level of efficiencies and responsiveness to customers not previously possible.ĭeveloping smart factories provides an incredible opportunity for the manufacturing industry to enter the fourth industrial revolution. Even higher value is created when data from production operations is combined with operational data from ERP, supply chain, customer service and other enterprise systems to create whole new levels of visibility and insight from previously siloed information. These smart factories are equipped with advanced sensors, embedded software and robotics that collect and analyze data and allow for better decision making. Manufacturers are integrating new technologies, including Internet of Things (IoT), cloud computing and analytics, and AI and machine learning into their production facilities and throughout their operations. Industry 4.0 is revolutionizing the way companies manufacture, improve and distribute their products.
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