Introduction
In today’s rapidly evolving landscape, the implementation of Industry 4.0 technology has become crucial for manufacturing plants. With the advent of industrial automation and the availability of reliable 4G/5G networks, Industry 4.0 or IIoT (Industrial Internet of Things) systems enable users to monitor and optimize critical assets, leading to enhanced productivity, quality, and sustainability. However, with the multitude of suppliers offering these systems, selecting the right one can be a daunting task. This blog aims to provide valuable insights on the importance of Industry 4.0 systems for manufacturing plants and offer guidance on selecting the ideal solution for your specific needs.
Why Industry 4.0 Systems are Essential for Manufacturing Plants: As global and domestic competition intensifies, manufacturing industries must strive to become leaner and more sustainable. Deploying Kaizen methodologies for continuous improvement is crucial, but decision-makers often lack visibility into whether these initiatives are sustained. This is where IIoT or Industry 4.0 systems come into play. By monitoring key performance indicators (KPIs), analyzing data, and generating reports, these systems enable data-driven decision-making. For example, they can determine the most efficient machine for producing a specific product, allowing organizations to optimize production planning based on actual performance rather than mere availability.
Benefits of Successful Industry 4.0 Implementation in Manufacturing: Successful implementation of Industry 4.0 systems in manufacturing industries has delivered a wide range of benefits, including:
A) Energy Savings:
Electrical: Up to 15% energy savings. Water: Approximately 10% reduction in consumption. Compressed Air: Around 10% decrease in usage. Fuel: Up to 15% reduction in fuel consumption.B) Productivity and Quality Monitoring:
Plan vs. Actual Production: Enables real-time tracking and analysis. Losses due to Quality/Availability/Performance: Identifies areas for improvement. C) Shop Floor Digitization:
Replaces manual entries with digital forms, streamlining processes. As per the CISCO report, 76 % of industrial IoT implementations fail.
We have analyzed the major reasons for failure as not identifying the exact need and suppliers’ lack of automation integration capabilities. With this in mind, we suggest having 6 stage defined plan as follows.
Identifying the Pain Point: Assess the specific challenges and pain points in your manufacturing plant. Implementing Proof of Concept (POC): Test a potential Industry 4.0 system in a controlled environment to evaluate its effectiveness. Cultural Adaptation of POC Team: Ensure that the team responsible for the POC is equipped to adapt and sustain the new system. Documenting Benefits and Internal Advertising: Clearly articulate the benefits of the POC and promote them internally to generate traction and support. Defining Industry 4.0 Strategy: Develop a comprehensive strategy that aligns with both the current and future needs of your manufacturing plant. Phased Implementation and Sustainability: Implement the chosen Industry 4.0 system in phases, track savings, and ensure long-term sustainability.Choosing the Right Industry 4.0 Implementation Partner
When selecting an Industry 4.0 implementation partner, consider the following criteria: Ability to deliver the 6-stage plan outlined above and showcase past success (check their PTRs). Possession of an internal cross-functional team comprising automation, IT, and application engineers with domain expertise. Capability to audit delivered savings and provide improvement solutions, displaying end-to-end ownership.