With each passing year, our world becomes a little “smarter.” Each
successive iteration of Internet technology produces a new generation of
machines that look familiar yet demonstrate an increasing ability to
learn from us and to automate our lives in surprising new ways. Just
consider how, in a relatively short period of time, we’ve gone from
landline phones to pocket-sized communication devices that know exactly
where we are and can predict where we’re about to go next—and even
suggest a route to avoid traffic. Or consider the fact that we can now
rapidly prototype virtually anything using CAD software and a desktop 3D
printer. Instead of talking about the Information Superhighway, we’re
contemplating a burgeoning Internet of Things (IoT) and Industry 4.0 in
which online devices wirelessly interact with other online devices in
real time, learning from one another and helping us apply the massive
amounts of data now floating around in cyberspace to live better, more
productive lives.
Such technology is already changing the way we live, work, and play.
That’s why forward-thinking manufacturers are preparing for a new era of
production in which human workers no longer operate machines; they
collaborate with them. After all, in an age of “smart” phones, “smart”
homes, and “smart” cars, it’s only a matter of time before we have
“smart” factories, too.
Welcome to the world of Industry 4.0. That’s shorthand for the next
wave of digitized automation in manufacturing, which focuses on the
disruptive potential of big data, extraordinary computing power, and
unprecedented virtual connectivity. The first generation of
industrialization involved mechanization, and the second generation
involved electrical automation and mass assembly. The third generation
arrived with the advent of computerized digital technology; and now,
with the introduction of the Internet and machine learning, we’re
heralding the dawn of fourth-generation paradigms.
Here are a few examples of what Industry 4.0 manufacturing looks like:
• Utilizing big data to streamline processes. Instead of merely
operating according to a set of programmed instructions, machines
optimize processes in real time by continually acquiring and analyzing
sensory data at multiple points along the production line. A high level
of interconnectivity between machines enables them to leverage the power
of distributed computing to establish complex metric histories,
contextualize data at particular capture points, and correlate
fluctuations in data against historical benchmarks. Plants therefore see
improved recovery rates and reduced input costs as machinery automates
routine QC checks and procedural adjustments.
• Digitally mapping physical entities for better design and process
engineering. In much the same manner as 3D modeling enables a user to
predict the output of a 3D printer, Industry 4.0 technology models
physical interactions between machines in cyberspace, enabling a plant’s
equipment to prototype and “test run” its production environment
digitally–without wasted assets. Errors can be more accurately
anticipated and addressed in the engineering stage rather than at the
point of production, and product designs can be optimized against
equipment capabilities.
• Enhancing personnel performance through more intuitive
human-machine interfaces. Biometrics, voice recognition, and augmented
and virtual reality technology enable more contextualized delivery of
information to human workers. This improves real-time decision-making,
reduces simple human errors, and automates record-keeping as employees
go about their jobs. Increasingly, humans and machines interact
according to a collaborative model as the unilateral “operator-tool”
mindset becomes obsolete.
Those are some monumental developments, and they represent a sea
change in how manufacturers may be doing business in coming decades. It
won’t be an overnight transition, of course, but for many, it’s not a
question of whether we’re moving in this direction, but of how quickly
we’ll get there. Manufacturers need to be ready, or they’ll be left
behind. We’re committed to helping you stay informed, because navigating
this emerging landscape requires visionary courage and a little help
from seasoned partners who know the terrain. Be sure to get in touch if you have questions about how automation technology can help you stay ahead of the curve.
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