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Industry 4.0

Consulting | Automation | Visualization

Industry 4.0

Industry 4.0

Consulting | Automation | Visualization

Industry 4.0 is bringing the physical and virtual worlds together

Industry 4.0 is bringing the physical and virtual worlds together

The Future of manufacturing is built upon four core foundations - digital twin, augmented reality, IoT platform, and edge computing. 

Future factories will be built twice: once virtually and again physically. Future functional tests on production equipment will be conducted using comprehensive simulation and virtual commissioning models. Head-mounted extended reality displays and cameras will improve significantly. Voice controls will be used by operators to collaborate and view digital twins, live videos, datasheets, and maintenance records while keeping their hands free to perform necessary tasks.

Aside from device integration and pure data management, we will see a greater emphasis on other features such as device management like security updates and business process management as Industrial IoT evolves. Simultaneously, bringing computational capacity out of the cloud and onto sites will result in a broader range of features, as well as real-time decision making, than fully online sites.

Edge computing will improve not only latency but also the security of smart systems as factories extend processing and storage capabilities to the edge. Because computing occurs closer to the data source, the risk of data leakage is reduced. Furthermore, edge storage alleviates the strain on cloud infrastructure by allowing manufacturers to send only relevant data to their cloud solutions. This reduces storage costs while also lightening the load on cloud-based analytics.

Industry 4.0 is bringing the physical and virtual worlds together
Implementing Industry 4.0: Challenges

Implementing Industry 4.0: Challenges

Implementing Industry 4.0: Challenges

The convergence of physical and virtual systems in smart factories will create new opportunities like predictive maintenance, XR-based remote diagnostics, maintenance and quality control, and tighter integration with ERP for better demand forecasting and resource planning. We will see significant improvements in productivity, performance, sustainability, agility, speed to market, and customization as a result of proper IIoT implementation.

To fully reap the benefits of industry 4.0, organisations must overcome the challenges of implementing large-scale solutions. The current workforce's lack of technical skills is a major impediment to smart factory deployment. From solution development to testing, deployment, and maintenance, the organisation must bring a diverse set of capabilities to the team.

The separation of protocols, components, products, and systems is another significant challenge. This lack of interoperability limits the options for upgrading system components and switching from one vendor to another. Furthermore, the abundance of data and leveraging it for business purposes can be difficult for organisations that do not have the right analytics tool and processes that can assist in assessing and utilising data.

Service Framework

Industry 4.0
Process analysis & optimization
  • Overall equipment efficiency
  • Overall line efficiency
  • Control & monitoring
  • Knowledge automation
  • Autonomous navigation
Factory Automation
  • Industrial gateways
  • Data lake creation and management on-premise and on cloud
  • Automated guided vehicles
  • Predictive analytics and maintenance
  • Plant performance analytics
  • AI-based video analytics
Design & visualization
  • Plant simulation
  • Digital twin 
  • Generative design
  • 3D modelling
  • AR/VR/MR applications  for operational & maintenance SOPS

Differentiators

  • Functionality-rich accelerators for offering flexible and scalable solutions
  • COEs for IoT, AI, and Extended Reality 
  • Partnerships with I4.0 Ecosystem (Automation and Sensors / Device OEMs & Industrial ISVs)

 

Benefits to customer

  • End to end I4.0 solutions design and implementation to significantly improve overall performance/efficiencies of manufacturing processes
  • Affordable solutions for a reduced total cost of ownership 
  • Post- Solution implementation, 24X7 run management support for infrastructure and platform 

 

Insights & Experiences

Traceability and Production Monitoring Solution
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Traceability and Production Monitoring Solution

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