Industry 4.0 emerged at the Hanover Fair in Germany in the early 2010s as the industry of the future, or the fourth industrial revolution. The concept is simple: to transform production methods through the integration of digital technologies. Its objective is just as simple: to meet the challenges of global competitiveness and productivity. Yet many business leaders still don't know what it's all about... What is Industry 4.0? Find out more about its origins, its key principles and all the reasons to adopt this intelligent factory today!
Origin and definition of Industry 4.0
Origin and development
Industry 4.0 originated in Germany, at the famous Hannover Fair in 2011. This innovative concept aims to revolutionise production methods by integrating digital technologies, automation and connectivity. Quickly adopted by other countries, Industry 4.0 is becoming a symbol of digital transformation and global industrial competitiveness.
But to better understand this new era, we need to look at the history of industrial revolutions:
- Industry 1.0 with mechanisation: at the end of the 18th century, the first industrial revolution introduced mechanisation thanks to hydraulic power and the steam engine. This advance revolutionised small-scale production, replacing it with machines.
- Industry 2.0 with electrification: at the end of the 19th century, the second industrial revolution introduced electricity and assembly lines, launching mass production. This period saw the emergence of major industrial management principles such as Fordism and Taylorism.
- Industry 3.0 with automation and globalisation: at the end of the 20th century, the third industrial revolution took hold with the advent of electronics and information technology, making it possible to automate tasks. We are also seeing a transfer of production to low-cost countries thanks to communication and containerisation.
- Industry 4.0 with digitisation: the introduction of digital technologies such as the Internet of Things (IoT), artificial intelligence (AI) and cloud computing is making it possible to connect machines, data and employees.
Definition and challenges
A 4.0 company is a company that has embarked on a digital transformation to connect its physical and digital organisation. It is built around two pillars:
- Connectivity: Industry 4.0 enables better connectivity between machines (Machine-to-Machine or M2M), between employees, but also between machines and employees. The main benefits? Coordinated processes and greater visibility and control over production.
- Automation: the automation of repetitive or complex tasks, with unprecedented precision and efficiency, is the second pillar of Industry 4.0. But this automation is not limited to physical processes. It also extends to decision-making processes, where AI analyses vast volumes of data to provide recommendations, anticipate breakdowns or optimise planning.
Technologies for Industry 4.0
Digital sensors
Equipped with internal intelligence (edge computing), digital sensors are the machine's nerve centre. They are capable of processing data in real time (curative action), but also of making diagnoses (preventive action).
Smart machine
The smart machine is the one that learns (machine learning). On the basis of information provided by digital sensors, it stores operating data and can then correct itself, or even ensure the quality of the parts produced. This interconnectivity also means that a product can be made to order as part of a series production run.
Internet of connected objects (IoT)
The Internet of Things (IoT) refers to the collective network of connected devices and the technology that facilitates communication between them. Used in Industry 4.0, it enables better connectivity between machines (Machine-to-Machine or M2M), between employees, and between machines and employees. The main benefits?Coordinated processes and greater visibility and control over production.
Big Data
The streams of information needed for analysis must be useful for production without slowing down the robots.They therefore need to pass through a different channel, which is what IO-Link technology makes possible. IO-Link technology, also known as edge gateway, distributes data flows.
Collaborative robots
Until now, robots have worked alone, but now they must work in collaboration with humans, particularly to relieve them of repetitive or complex tasks. Certain categories of robots are also capable of alternating between a high rate of speed in the absence of humans and a more collaborative rate of speed when there are operators in their work area.
Benefits of Industry 4.0 for businesses
The main advantage of Industry 4.0 is its competitive edge. Adopting Industry 4.0 is essential if you want to remain competitive. And this on five levels.
Efficiency and productivity
Automation and artificial intelligence technologies reduce production time, while increasing product quality.Processes become faster, waste is minimised and customer satisfaction is enhanced.
Cost reduction
Industry 4.0 reduces costs through early detection of faults. Predictive maintenance avoids costly repairs and reduces unplanned downtime. By automating repetitive tasks, human resources are also put to better use, while optimisation significantly reduces energy bills. These savings boost companies' profitability and competitiveness.
Safety and real-time control
Advanced technologies, such as connected sensors and predictive analysis tools, enable continuous monitoring of equipment and processes. This means that faults can be detected before they occur, reducing production stoppages and the risk of errors. These technologies also make it possible to predict when maintenance needs to be carried out, sometimes even making an appointment with a technician.
Innovation and flexibility
Industry 4.0 doesn't just optimise existing processes: it paves the way for continuous innovation. Markets evolve rapidly, and companies need to be able to adapt just as quickly to changing demands. Thanks to cutting-edge technologies such as artificial intelligence and the Internet of Things, you can design innovative new products.3D printers, for example, enable you to produce prototypes, manufacture complex shapes and create highly customised products to your customers' specifications.
Real-time data on customer preferences and product performance, meanwhile, provides valuable insights for anticipating market trends and responding with appropriate solutions.
Sustainability and environmental responsibility
As you know, sustainability requirements are higher than ever. Industry 4.0 offers concrete solutions for reducing your environmental impact. Digitising paper documents minimises waste and ensures that raw materials are used sensibly. In addition, process optimisation and intelligent systems can reduce energy consumption.
To conclude: what is Industry 4.0?
Industry 4.0 is a veritable revolution in the industrial world. It is redefining standards of competitiveness and productivity. This is achieved by integrating technologies such as connectivity, automation, the Internet of Things and artificial intelligence.
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