Part 2: Core Technologies of Industry 4.0

An overview of the technologies driving Industry 4.0, including artificial intelligence, IoT, robotics, and big data analytics, and how they redefine manufacturing.

Mar 10, 2024

Photo by NanoStockk

👋 Hey, it’s Sara. Welcome to my weekly newsletter where I share insights to become more efficient. Each week, there will be a featured article, a glimpse into technology, a throwback to the past, and community conversation.

Read time: 7 minutes

History and experience tell us that moral progress comes not in comfortable and complacent times, but out of trial and confusion. — Gerald R. Ford

Last week, I attended the American Small Manufacturing Coalition’s Hill Day in Washington DC. Our purpose was to advocate for funding for the Manufacturing Extension Partnership. Over the course of the week, I spoke with several colleagues about Industry 4.0 and one thing remains clear. The definition is not simple, nor easily explainable, unlike the previous Industrial Revolutions. The fusion of physical things, digital technology and people is an obscure concept. Luckily, the technology that defines Industry 4.0 is easier to explain. In this article, I’ll provide a high-level introduction to each technology.

Additive Manufacturing

Additive Manufacturing, or 3D printing, is building an object layer by layer, based on digital models. It allows greater design flexibility and material efficiency. Additive manufacturing is often used in rapid prototyping and provides an alternative solution to produce parts in low volume. Considerations include the size of available printers, material selection and time. Additive manufacturing can be slow for mass production.

Artificial Intelligence (AI) and Machine Learning (ML)

Artificial Intelligence is a broad concept that refers to machines or computers doing tasks that require human intelligence. Machine learning is a subset of artificial intelligence, where a program can learn from historic data to make a prediction. ML can improve over time with more data without a human intervention. The data can include images, video, text and sensor data, opening up a wide range of possibilities to build and train models for various outcomes.

AI is integrated into our lives already - streaming a video, making an online purchase or using navigation in your car? AI is working behind the scenes to make things easier and more suitable. In manufacturing, AI can predict equipment failures, be used to quality parts, and optimize production processes.

The downside of AI / ML is that large datasets are required for training. The process of collecting data, cleaning it, and labeling it can take a lot of time and effort. There are also concerns over ethics, as the models can be biased.

Augmented Reality (AR) and Virtual Reality (VR)

AR overlays digital information on the real world, while VR creates immersive, simulated environments. In many newer cars, the speed or other data such as directions, is projected onto the windshield. My kids use an Oculus, Meta’s VR, to play video games with their friends.

In my career, I’ve tried Augmented Reality with glasses. The challenges included the physical glasses themselves and the time needed to create the AR content. For remote assistance, however, the time to value is very low. For example, sharing schematics digitally, in real time to a field worker is useful and takes little investment beyond the physical equipment and software.

AR Example - 19 Crimes Wine Bottle. My favorites include Snoop Dogg and Martha Stewart.

Big Data and Analytics

Big Data and Analytics are technologies that process and analyze large volumes of data to uncover patterns, correlations and trends. Visual tools such as Tableau, PowerBI, or Qlikview, provide analysts the ability to discover pattens in data quickly, as well as provide companies with metrics that include drilldown capabilities. Apple Watches and other fitness trackers analyze steps and sleep patterns to provide recommendations. While creating this newsletter, my watch has alerted me to stand up at least twice.

Blockchain

Blockchain is a secure, distributed ledger technology that records transactions across many computers, preventing alterations. The most common application is crypto currencies, such as Bitcoin. In industry, blockchain can be used to track components through the supply chain and in smart contracts. Its implementation can be technically challenging, and the energy consumption of certain blockchain types is a concern.

Cloud Computing

Cloud Computing is the delivery of computing services over the internet, allowing for flexible resource use and data storage. When the computing services need more power, the computation power is increased seamlessly. In order to do the same thing with a physical server, you need to add hardware. The cloud is also useful for data storage. Take photos for example, on a phone there is a limited number of photos that can be stored, however, when they are moved to the cloud, your storage is only limited by how much money you want to spend. The downside of cloud computing is that internet connectivity is required, as well as an increased risk in data security.

Cyber Security

Cyber Security is the protection of internet-connected systems, including hardware, software and data from cyber-attacks. Unfortunately, with massive amounts of data and transactions happening over the internet, it is a target for theft and ransom. Advances in technology such as facial recognition on a phone, and 2-factor authentication has reduced the risk of cyber-attacks and theft. Due to the rapid increase in technology, cyber security needs to be evaluated and security measures need to keep up to reduce risks.

Internet of Things (IoT)

The Internet of Things refers to physical devices embedded with sensors, software and other technologies for the purpose of connecting and exchanging data over the internet. The connectedness allows for more integration of the physical world into computer-based systems. In our home, we have adopted security cameras and garage door openers that have phone apps.

In manufacturing, IoT devices can monitor production processes, and the data can be used to optimize them. Sensors can predict equipment failures before they occur, and the maintenance can be scheduled accordingly. Even production can be adjusted in real-time to reduce the downtime.

IoT offers significant benefits, but it also raises concerns regarding security and privacy. Integration of devices and ensuring communication can be problematic as well. Support open platforms and frameworks that encourage interoperability and allow for the integration of devices from different ecosystems. Measures can be taken such as anonymization and encryption to protect privacy.

Robotics

Robotics involves the design, construction, operation and use of robots to perform tasks autonomously or with minimal human intervention. Robots are programable machines that can manipulate objects, move with precision and perform tasks that are challenging for humans. Robotic vacuum cleaners are becoming more common - although if I’m honest, I haven’t had one that I liked yet. Our last purchase randomly moved, and I never felt confident in its ability.

In manufacturing robots are used extensively for assembly, welding, and material handling. They can work in environments that are dangerous or unsuitable to humans. While the productivity gains are significant, robots require substantial investments and training. Safety needs to be considered during implementation to prevent accidents between humans and robots.

Together, these technologies form the backbone of Industry 4.0, revolutionizing how industries operate by making processes smarter, more efficient, and interconnected.

Tech Spotlight: 4D Printing

While putting together this article, I stumbled upon 4D printing, a concept that I hadn’t heard before. I kindly asked Gemini to help me summarize a Ted Talk on YouTube.

In a TED talk by Skylar Tibbits, a researcher at MIT, he introduces a new concept called self-assembly [1]. Self-assembly is a process by which disordered parts build an ordered structure through local interaction. Tibbits argues that self-assembly can revolutionize construction and manufacturing industries [1].

Tibbits proposes that we can combine these two worlds to create programmable materials for the built environment [1]. He envisions materials that can self-assemble into pipes, furniture, or even buildings [1].

One example is a project called self-folding proteins [1]. Here, a three-dimensional protein structure is broken down into a series of components. These components can then self-fold back into the original protein structure [1].

Tibbits also talks about 4D printing, a new concept that allows 3D printed parts to transform themselves after being printed [1]. This is achieved by using multi-material printing and exploiting the transformation properties of the materials [1].

The video concludes with Tibbits calling for collaboration across different industries to develop self-assembly materials for the built environment [1]. He believes that self-assembly has the potential to revolutionize construction and make it more efficient and less labor-intensive [1].

Attributions: [1] The emergence of "4D printing" | Skylar Tibbits Link to Video

Community Conversation

Do you have other questions do you have that I can answer here? Answer in the comments or hit me up on LinkedIn.

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Until next time, thank you for your support and curiosity.

— Sara 🙋‍♀️

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Erie, PA 16415, USA

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