Industry 4.0: an overview from the perspective of a German-headquartered firm (1.st Part)

Industry 4.0: an overview from the perspective of a German-headquartered firm Dr. Peter Köhler, Chief Executive Officer Dr. Björn Six, Vice President Business Unit Machinery Solutions Dr. Jan Stefan Michels, Vice President Standard & Technology Development Weidmüller Group

1. BASIC UNDERSTANDING OF INDUSTRY 4.0 Ever since it was first unveiled at the Hannover Messe 2011, the world of industrial and production technology has been preoccupied with the term Industry 4.0 (and its synonyms Integrated Industry and Advanced Manufacturing). Industry 4.0 represents a realignment and paradigm shift of industry that redefines work structures in companies - from planning, through to implementation, all the way to sales. The latest surveys reveal that many decision-makers in Germany and Central Europe still don’t know what the term Industry 4.0 is all about (CSC 2014). Especially the specific benefit and the potential of Industry 4.0 concepts and technologies in production and in the value creation networks are (still) not apparent for many companies. While the technological concepts are largely rather well developed, the fantasy to imagine how specific applications look and what quantifiable benefit could thus arise is found to be lacking in many cases. At the same time, the business models for horizontally and vertically networked value creation chains still need to be further developed and the technical, cooperative and partly also legal conditions for this have to be created. Against this backdrop, this article aims to provide a basic understanding of this topic and an overview of the goals and challenges associated.

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1.st Part

1.1. What is Industry 4.0?

Industry 4.0 is the name given to the fourth industrial revolution (the following deliberations are based on Bauernhansl, 2013). The first industrial revolution took place in the 18th century, driven by the development of the steam engine and the mechanical production facilities it brought about. Essentially, these installations enabled the industrialisation of work previously accomplished manually and resulted in considerable increases in productivity and prosperity. This affected the food, textiles, iron and steel industries, as well as steam navigation and railways. The second industrial revolution can be assigned to the start of the 20th century and was characterised by mass production of standardised goods based on the division of labour, as described by „the father of industrial engineering“ Frederick W. Taylor - with the use of electrical energy and drive systems. Large-scale mass production became possible, especially in the chemical, electrical and automobile industries and mechanical engineering. The third industrial revolution in the 1970s was again characterised by progressive automation of production processes. This was enabled by the entry of electronic and information/communication technologies into routine production. This allowed production processes to be

designed more efficiently, series production with many variants also became possible for the first time. Today we stand on the threshold of the fourth industrial revolution. It is largely characterised by Internet technologies and networking in production. In contrast to the first three revolutions, which took place abruptly, the fourth industrial revolution will be more a continuous process.

So what exactly is behind the fourth industrial revolution or Industry 4.0? According to "Plattform Industrie 4.0“ from the German Federal Ministry for Economic Affairs and Energy, this term describes a new stage of organisation and control of the entire value creation chain across the product lifecycle, essentially driven by increasingly individualised customer wishes and a continuous rise in market complexity (Kagermann/ Wahlster/Helbig, 2013). The key facets and the basis of these new control mechanisms are availability of all the relevant information in real time by means of networking all parties involved in value creation (> Availability and networking of data), as well as the ability to determine the current process status at all times from the data (>Analysis of data, in the cloud where appropriate) and from this to derive the optimum value creation flow (>Deduction of value chain optimising measures/optimisation). These relationships are presented in the following Abbildung 1.

Figure 1. Data availability, analysis and optimisation as essential aspects of Industry 4.0.

According to the definition stated here, the fourth industrial revolution applies equally to technologies, systems and processes, as well as their complex interaction. The coalescence of production technologies and products, as well as networking of the components and (sub)systems affected is

services is rising steadily. Various studies assume a growth of up to 50 billion networked devices by 2025 and a large proportion of these devices are found in the production context. Two years ago, an estimated 2.5 trillion bytes of data was produced worldwide with these devices - daily! The number of available apps and services is growing even faster than the number of devices. Deloitte 2015 assumes a growth around 4-5 times higher. Abbildung 2 provides an overview of the predicted development of the quantity of networked devices.

The real and virtual worlds are coalescing with increasing digitalisation, the physical capabilities of objects are supplemented by the digital properties and capabilities.

This development affects different application areas, such that a division into three areas has become established among experts: the Internet of Things, of services and of people (Dais, 2013). As discussed above, the Internet of Things relates to the networking of different devices and enables novel concepts, such as the Smart Home, the Smart Grid or the Smart Factory – Industry 4.0. The development of novel applications is often termed as the Internet of Services, which virtually models and steers business processes. Finally, the Internet of People is the term used for the Internet applications known from daily life, the social media certainly have a special influence here. Continuous digitalisation is progressing at the highest speed in this area. As a consequence, we are already very familiar with the Internet of People from everyday life, we are now on the threshold at which the domains of the Internet of Things and the Internet of Services are consequently of increasing importance.

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Continue in the next edition.

LITERATURE t acatech (2011). Cyber-Physical Systems – Innovationsmotor für Mobilität, Gesundheit, Energie und Produktion