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Industry 4.0 and Smart Factory

January 2017

DOI:10.13140/RG.2.2.36253.00485

Conference: Maker Faire Cairo 2017
At: Smart Village, Cairo
Affiliation: Associate Professor

Authors:

King Fahd University of Petroleum and Minerals

The fourth industrial revolution Industry 4.0 represents a new paradigm shift from “centralized” to “decentralized” industry relies on cyber-physical based automation where sensors send data directly to the cloud and services such as monitoring, control and optimization automatically subscribe to necessary data in real-time. In the coming years, these technologies will be seen as a viable alternative to current manufacturing processes. According to a recent report by Markets and Markets, smart factory technology will have global market size of 74.80 Billion USD by 2022. The talk provides a comprehensive introduction to Industry 4.0 and Smart Factory. Technical challenges and social implications of smart factory will be discussed. The applicability of these emerging technologies in developing economies is highlighted in this talk as well.

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Industry 4.0 and Smart Factory

Alaa Khamis, PhD, SMIEEE

Head of Advanced Development Division at Sypron Solutions

http://www.alaakhamis.org/

Maker Faire Cairo 2017 © Dr. Alaa Khamis

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2017 © Dr. Alaa Khamis

OUTLINE

What is Industry 4.0?

Why Industry 4.0?

Challenges

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2017 © Dr. Alaa Khamis

WHAT IS INDUSTRY 4.0?

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2017 © Dr. Alaa Khamis

WHAT IS INDUSTRY 4.0?

Source: Lev Grossman, “2045: The Year Man Becomes Immortal,” TIME Magazine, February, 2011.

•Human Scientific Progress

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2017 © Dr. Alaa Khamis

WHAT IS INDUSTRY 4.0?

Agriculture revolution

Industrial revolution Light bulb Moon landing World Wide Web

Human Genome

Sequenced

8,000 years

120 years 90 years 22 years

9 years

•The accelerating pace of change

Source: Lev Grossman, “2045: The Year Man Becomes Immortal,” TIME Magazine, February, 2011.

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Time to reach 100 Million customers

Telephone

75 Years

Web

7 Years

Facebook

4 Years

Instagram

2 Years

Pokemon Go

1 Month

WHAT IS INDUSTRY 4.0?

•The accelerating pace of change

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2017 © Dr. Alaa Khamis

WHAT IS INDUSTRY 4.0?

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WHAT IS INDUSTRY 4.0?

Mechanization

Electrification

Automation

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Cost-efficiently

Quickly

Flexibly

WHAT IS INDUSTRY 4.0?

Shorter lead

time/product

life cycle

Larger product

variance

For both large volume and

small quantities

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WHAT IS INDUSTRY 4.0?

Digitalization Automation Connectivity Analytics

Source: B. Roland, "INDUSTRY 4.0: The new industrial revolution How Europe will succeed," Think Act, Tech. Report, 2014.

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WHAT IS INDUSTRY 4.0?

Emerging Cyber Physical

System-based Automation

Classical 5-Layer Automation

Architecture

ERP

MES

SCADA

PLC

Sensors-Actuators

Factory Operation

Management Level

Process

Control Level

Cell Level

Station Level

Machine Level

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•Global Market Size Forecast in 2019 (USD Billion)

WHAT IS INDUSTRY 4.0?

Smart Factory technology will have global market size of 74.80

Billion USD by 2022. [Markets & Markets]

293.57

115

62.98

29.53

15.25

5.3

100

150

200

250

300

IoT Big data Smart Factory Advanced Analytics Service Robotics Smart Machines

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WHY INDUSTRY 4.0?

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WHY INDUSTRY 4.0?

Better Quality

Increased

Productivity

Sharing

Economy

Improved

Decision

Making

Mass

Customization

Faster

Production

Industry 4.0

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WHY INDUSTRY 4.0?

Increased flexibility in production and manufacturing on demand

•Mass Customization

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WHY INDUSTRY 4.0?

Virtual modeling of manufacturing process

•Faster Production

Digital designs

Speed up the manufacturing

process :

Data-driven supply chains

120% in time needed to

deliver orders

70% in time to get

products to market

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WHY INDUSTRY 4.0?

•Better Quality

Siemens Smart factor for custom Programmable Logic Controls (PLCs)

500

100

200

300

400

500

600

1989 2015

Number of defects per million units

99.99% reliability rate

Top 100 European manufacturers could save

an estimated €160 billion in the costs of scrapping

or reworking defective products if they could

eliminate all defects.

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WHY INDUSTRY 4.0?

•Increased Productivity

Lights out/Dark factories work 24/7

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WHY INDUSTRY 4.0?

•Increased Productivity

Predictive maintenance

avoids machine failures on the

factory floor

50% decreased downtime

20% increased production

Predictive maintenance will

help companies save $630

Billion by 2025 [McKinsey]

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WHY INDUSTRY 4.0?

•Sharing Economy

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WHY INDUSTRY 4.0?

•Improved Decision Making

With access to factory and cross-market data, decision makers

can predict, response, and adapt

to factory needs and market trends

CHALLENGES

General reluctance to change by stakeholders

Lack of adequate skill-sets

Unemployment

Communication reliability and QoS

Cyber security

Maturity of machine intelligence

Handling big data

Technical Challenges

Social Impact

CHALLENGES

•Big Data

CHALLENGES

•Big Data

RADAR: ~10-100 KB per second

SONAR: ~10-100KB per second

Camera: ~20-40 MB per second

LIDAR: ~10-70 MB per second

GPS: ~50 KB per second

Autonomous Vehicle

4 TB

Per Day

CHALLENGES

•Social Impact

CHALLENGES

•Social Impact

A study out of Oxford

University in 2014 found that

in the near future artificially

intelligent technology

could take over nearly

half of all U.S. jobs.

We can expect a wave of structural unemployment to spring

from the technology in the medium term.

CHALLENGES

•Social Impact

Better in Dull

Dangerous

Dirt

Dumb

Robots find

applications in

“4D tasks”

CHALLENGES

•Social Impact

CHALLENGES

•Social Impact

Machine Human

Creative

Lower initial cost

and higher running

cost

Faster

More precise

Able to work in harsh environments

Higher initial cost and lower running

cost

Thank you for your attention!

Questions?

Decision Making Support for Quality 4.0 Using a Multi Agent System

Chapter

Jan 2022

Recently, the fourth industrial revolution comes with a very important advantage that solves the difficulties faced by the companies regarding customer satisfaction in terms of quality, as the demand is instantly changing; the production process needs to be more flexible and reactive to deliver the product in the defined time with the desired quality. Therefore, this paper focuses on the production and quality management and gives a brief introduction of the quality 4.0 and multi-agent system, and then we present our field of study related to modeling a multi-agent system of the new quality 4.0 where we identified three main agents: quality control, quality cost improvement and quality planning agent, using MaSE methodology in order to have an efficient decision making. KeywordsQuality 4.0Industry 4.0Customer satisfactionMulti agent systemMaSE

The Implementation of Smart Factory for Product Inspection and Validation A step by step guide to the implementation of the virtual plant of a smart factory using Digital Twin

Conference Paper

Jun 2021

ResearchGate has not been able to resolve any references for this publication.

Industry 4.0 and Smart Factory

Abstract and Figures

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