Industry 4.0 in Metals

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By Tarun Mathur  LinkedIn
ABB Metals Digital Lead

About the author
Tarun Mathur graduated from the Indian Institute of Technology, Mumbai and holds a Master’s degree in mathematical modeling and process control.

He has held several positions in R&D focusing on the development of advanced model-based solutions for process industries.

Tarun is currently focused on projects applying new digital technologies to optimize metals plant performance, processes and quality.

As we started talking to a cross-section of audiences, primarily customers working in the metals segment, we realized that there is an extensive buzz around and curiosity in the Industry 4.0 phenomenon. Everyone we spoke to, without exception, realizes the far-reaching impact that the introduction of digitalization can enable at their metal plants.

However, we also found ourselves often explaining the nuances of the practice and the various terms and jargon that have emerged as a result. So, we thought we’ll create a resource for a clear understanding of these new terms and a brief explanation of what Industry 4.0 actually is.  

Businesses of the future – Industry 4.0

I regard Industry 4.0 as heralding the arrival of a new era in industrial operations, defined by the adoption of hyperconnected systems. In generally accepted terminology, Industry 1.0 refers to the industrial revolution that brought steam power; 2.0 saw electricity transform assembly line mass production and Industry 3.0, the adoption of computers and automation.  

I think that lines blur between where Industry 3.0 ended and 4.0 began as the age of digital impact shifted to more than just automation.

Manufacturing, as we know it, is changing in a big way. We are no longer talking about just automating processes.
I believe that manufacturing, as we know it, is changing in a big way. We are no longer talking about just automating processes and systems but also about harnessing real-time data, analytics, machine learning, artificial intelligence and other technologies with interconnected devices. In this age of smart machines, systems talk to each other, reducing human involvement by their ability to make decisions. We are using the power of this new trend to enable paradigm changing practices such as predictive insights. This has found application in several industries, metals included.  

 

In this age of smart machines, systems talk to each other, reducing human involvement by their ability to make decisions.

We are using the power of the new trend to enable paradigm changing practices such as predictive insights.

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Building blocks of Industry 4.0

In my experience, the core premise behind Industry 4.0 lies in the increasing ease of generating, classifying, storing, accessing and analyzing data. Data, today being generated in very high volumes, forms the core building block of Industry 4.0. When systems collect data, information is used by the machines to interpret it for improved performance. 

 

Big data refers to the extraordinary volume of data that is constantly generated and made available for analytics. The sources and forms of data may vary but smart machines are designed to receive and interpret big data sets cohesively and produce a large number of insights.  

 

The process of data collection and management is driven by the Internet of Things (IoT) – a network of devices built around electronics, sensors and actuators, connected to interact and exchange data. Industrial IoT (or IIoT) describes a set of machines and systems that are connected by the internet, in the context of running plant operations. 

 

With sufficient instances of data collection and analysis, assets are being made smart enough to respond to data triggers by themselves – creating “self-reporting” and “self-performing” assets. Through this process of machine learning, the industrial world is being driven by smart machines that recognize patterns and flag problems; with quick solutions for them. On the assembly line, data drives the information pathway to address lags and delays more effectively than ever before. 

 

Machine learning constitutes a major component of IIoT. With higher analyzed data fed into smart machines, they are able to function and respond better. This self-learning over time is the artificial intelligence that is built into the machine.  

Industry 4.0 implementation experience

Get started with Industry 4.0 implementation

Sneak peek

No digitalization effort is complete unless operational technology is closely integrated with information technology with a proper IIoT architecture.  More on this in my next blog...

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