Automotive Industry in the Context of Industry 4.0 Strategy

Abstract

The emergence of cyber-physical systems encourages constant adaptation to the complex requirements of new systems, creating new requirements for businesses that must adapt their activity to change. The automotive industry is the decisive industry and the driving force behind the development of the Slovak economy. Changes that have occurred in the automotive industry are reflected in the high automation of processes, which is reflected in the need to change management, in particular the need for on-line automotive tracking.

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Transactions of the VSB - Technical university of Ostrava
Safety Engineering Series, ISSN 1805-3238
Vol. XIII, No. 2, 2018
61
AUTOMOTIVE INDUSTRY IN THE CONTEXT OF INDUSTRY
4.0 STRATEGY
Juraj SINAY1, Zuzana KOTIANOVÁ2
1 Technical University in Košice, Faculty of Mechanical Engineering, Košice, Slovakia, juraj.sinay@tuke.sk
2 Technical University in Košice, Faculty of Mechanical Engineering, Košice, Slovakia, zuzana.kotianova@
tuke.sk
Abstract: The emergence of cyber-physical systems encourages constant adaptation to the complex
requirements of new systems, creating new requirements for businesses that must adapt
their activity to change. The automotive industry is the decisive industry and the driving
force behind the development of the Slovak economy. Changes that have occurred in
the automotive industry are refl ected in the high automation of processes, which is refl ected
in the need to change management, in particular the need for on-line automotive tracking.
Keywords: Safety; industry 4.0; sensors; automotive industry; risks.
Review article
Introduction
Slovak industry is focused on the area of
automotive industry. The automotive industry creates
more than 44% of the total GDP in industry, which
is up to 26% in the Slovak Republic. The objectives
of car production - increasing their number on
markets, the latest technologies with a high degree
of digitization and automation are being used in this
industry sector. Since the adoption of the Intelligent
Industry Concept for Slovakia (October 2016),
a clear position of the Government and Ministries
on this topic is already in place in Slovakia, and
Industry 4.0 is becoming a national priority. It is
a necessary and anticipated process for maintaining
competitiveness. Implementation of intelligent
industrial processes will change not only Slovak
production companies, but will also become
the cornerstone of development of Slovakia's
economy with a signifi cant impact on society.
Materials and methods
Industry 4.0
The term Industry 4.0 (Fig. 1) means a way
of managing activity within technologies where
production and logistic processes, and within them
machines and products, communicate with each
other and organize individual steps in the production
process autonomously and in synergy with the human
factor. The goal is for the processes to consider
the requirements for safe operation so that, at the end
of production process, the products meet customer
requirements. Companies are heading towards
the so-called Smart Factory.
The term Industry 4.0 represents:
• linking production to information and
communication technologies;
• linking customer requirements directly with
machine and device data;
• communication of machines with machines;
• autonomous data acquisition and processing at
both vertical and horizontal level;
• decentralized management;
• separate production created by communication
between semi-fi nished products and machinery
- fl exible, effi cient and economically saving
resources (Pattform 4.0. 2018).
Fig. 1. Industry 4.0 (touchit.sk, 2017)
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Safety Engineering Series, ISSN 1805-3238
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Industry 4.0 is based on two main cornerstones:
1. digitization - products, processes, equipment,
services;
2. application of exponential technologies.
Industry 4.0 brings technical and social
development to the current world of work.
One of the strategic tasks in the near future is
the interconnection of adequate education, currently
known as Education 4.0, based on the results of
applied research and innovation, to Safety 4.0,
Prevention 4.0, Quality 4.0, and the like (Fig. 2).
Fig. 2. New challenges in Industry 4.0
The increasing degree of digitization causes
changes in the nature of work. New communication
models, new forms of work /homeworking/ as well
as new professions will emerge. This means that
there are not only changes in technology but also
in the area of work. This results in:
- new forms of hazard identifi cation and risk
assessment,
- development of new methods, procedures and
instruments for identifying new risk parameters.
It follows that meeting the requirements of
Industry 4.0 will have the necessary impact on:
• quality of work,
• requirements for qualifi cation,
• new ways of organizing work and changing of
many interactions and interactions in the human-
machine-environment interface that we can
imagine as new forms of collaborative work in
the context of a digital factory.
Individual companies according to the degree
of implementation of Industry 4.0 elements can be
partitioned, for example, to fi ve levels. Each level has
a specifi c division of Integrated Safety & Security.
The individual levels of Industry 4.0
implementation:
1. Level - Basic level of digitization: The company
does not address sector 4.0, requirements are not
met or only partially met.
2. Level - Digitization between departments:
the company is actively engaged in the topics
of Industry 4.0. Digitization is implemented
in various departments and the fi rst requirements
of Industry 4.0 are implemented throughout
the company.
3. Level - Horizontal and vertical digitization:
The company is digitized horizontally and
vertically. The industry 4.0 requirements
were implemented within the company, and
the information fl ows have been automated.
4. Level - Full digitization: The company is fully
digitized beyond enterprise boundaries and
integrated into value networks. Approaches
in industry 4.0 are actively pursued and embedded
within the corporate strategy.
5. Level - Optimize Full Digitization: The Company
is a model for industry 4.0. Strongly cooperates
with its business partners and therefore optimizes
its value networks.
Cyber-physical Systems
Cyber-physical Systems, Fig. 3 (hereinafter
referred to as CPS) represent the link between
real (physical) objects and processes processing
information (virtual-cybernetic), often operating
over an open, partially global and interconnected
information network. It is a dynamic and
meaningful course of production that may result
in data, information, and services found on
external production networks being taken back,
if necessary. Thanks to these functional capabilities,
the devices become adaptive, self-managing
and self-confi guring, or possibly self-optimizing
production components (Huber, 2016).
CPS represents:
• fl exible (SMART) machines, devices, goods and
components;
• system functionality of these devices distributed
over the network;
• hierarchy of interconnected components;
• communication between components;
• product as part of the network (Industry4, 2018).
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Fig. 3. Cyber-Physical Systems (Industry4.sk,
2018)
CPS, as all other technologies, enable further
optimization and improvement of production. CPS
are seen as a means to control the ever-increasing
complexity of the production industry. Developed
CPS sensorics enable real-time collection of data
in huge quantity and various structure, which enables
the systems to predict future behaviour, to analyse
errors, and to evaluate and make decisions. These
complex systems are referred to as "Big Data" and
are part of the so-called Smart Data (autonomously
controlled and responding data systems, such as
data lifecycle, 3D reporting, predictive maintenance
and quality, etc.). CPS actuators which operate
autonomously are used to implement these decisions,
i.e. the performance of control instructions, and
they enable continuous performance of the control
system while responding to external and internal
stimuli (Gregor, 2016).
According to Obermeier, the starting point for
understanding CPS is the understanding that every
object that works on the basis of the so-called built-
in systems with automatic control capability, and
equipped with sensors able to capture data, software
for their processing and evaluating the effects of real
phenomena of data structures such as the Internet,
enables communication in the interface man-
machine-environment, and the repeated process with
the other CPS can be connected into one network,
the so-called Internet of Things (IoT) and Internet of
Services (IoS).
Automotive Industry versus Industry 4.0
Slovak industry is oriented towards
the automotive industry; therefore, the individual
elements of Industry 4.0 are applicable in this
direction. With respect to technological advances,
there are many factors in this sector, particularly
the high level of automation and digitization.
Automotive industry elements of Industry 4.0 are:
- augmented reality, using virtual simulations to
design workplaces, processes, and setup and
repair machines;
- virtual assembly, which allows employees to
estimate how to best handle the task by means of
control module (Oravec et al., 2017);
- 360-degree networking (Mixmotor, 2015);
- autonomous robots and machines, based on
cooperative partnership machine-machine,
machine-man that frees man from risky activities;
- Smart Factory, by incorporating the real world
into the digital world it is possible to create
the so-called digital twin that allows real-time
display of processes, systems and entire production
halls;
- higher fl exibility, faster response of production
to global market fl uctuations and individual
customer demand. Digital production also
facilitates the production of increasingly more
complex products;
- increased effi ciency, cost-effective use of
resources as well as energy, buildings or inventory
is a decisive factor;
- higher speed, fl exible production processes,
simplifi ed adaptation of existing production
facilities and installation of new equipment enable
easier and more effi cient manufacturing processes.
This allows for shorter innovation cycles; product
innovations can be quickly introduced on
the market;
- intelligent logistics, from confi guration
and ordering vehicle by customer, through
identifi cation of the need for constructional
components and their procurement to production
and shipping;
- 3D printing, especially in additive production or
development and subsequent testing.
Horizontal and vertical system integration
enabling data fl ow control across company and
corresponding software equipment - this allows for
use of complete 3D information along the entire
value chain (Fig. 4).
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Transactions of the VSB - Technical university of Ostrava
Safety Engineering Series, ISSN 1805-3238
Vol. XIII, No. 2, 2018
64
Fig. 5 illustrates the data fl ow in Industry 4.0,
where it can be said that from safety point of view,
the hierarchy of risks begins with the sensor. It is
necessary to look for new methods and procedures
in the process of identifying and managing risk
suffi ciently taking into account communication
fl ows, data mobility and their characteristics,
the amount of data being processed and assessed,
and the way they are managed. Industry 4.0
represents fl exible production of highly personalised
products by means of collaborative robots and other
mechanisms. Their autonomy, however, comes with
the potential to create new hazards and is therefore
one of the top topics addressed in the context of
occupational safety - there is a real risk of collision
between robot and man.
Results
Types of risk in the context of Industry 4.0 can be
summarized as follows:
- new forms of risk resulting from using new
technologies;
- unreliable operation of sensors;
- bad transmission of information;
- new work activities in new conditions;
- increasing trend of psychological risks;
- information risk related to loss of data and loss of
company know-how;
- risk of collision or pressing an employee by
a collaborative robot;
- risks related to home working;
Fig. 4. Difference in Information Flow within
Industry 3.0 and 4.0
From the point of view of use, sensors can be
divided into:
a) safety sensors,
b) operational sensors,
c) communication sensors.
Fig. 5. Data Flow within Industry 4.0 (Obermaier, 2016)
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Transactions of the VSB - Technical university of Ostrava
Safety Engineering Series, ISSN 1805-3238
Vol. XIII, No. 2, 2018
65
requirements, new ways of organizing work and
changes of interactions and synergy in man-
machine-environment interface that we can imagine
as new forms of collaborative work in the context of
a digital factory.
Acknowledgements
This contribution was developed by
implementing APVV-15-0351 "Development
and Application of Risk Management Models in
Conditions of Technology Systems in Compliance
with Industry 4.0 Strategy".
- sensitivity and vulnerability of data related to
cyber attacks;
- small number of qualifi ed employees;
- electromagnetic emissions.
Conclusion
Within the current progress of Industry 4.0, safety
is monitored at the level of achieved intelligence of
robots of industrial equipment as well as at the level
of system and communication security of data and
their management.
Implementation of the framework focus
of Industry 4.0 requirements will have an
inevitable impact on quality of work, qualifi cation
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