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BAHÇEŞEHİR UNIVERSITY
A FRAMEWORK FOR THE GENERIC
IMPLEMENTATION OF INDUSTRY 4.0 INTO NONAUTOMATED AND NON-INTEGRATED SYSTEMS
Capstone Project
Bengisu Özer,
Berfu Arslan,
Mücahit Şahin
İSTANBUL, 2018
T.C.
BAHÇEŞEHİR UNIVERSITY
FACULTY OF ENGINEERING AND NATURAL SCIENCES
DEPARTMENT OF INDUSTRIAL ENGINEERING
A FRAMEWORK FOR THE GENERIC
IMPLEMENTATION OF INDUSTRY 4.0 INTO NONAUTOMATED AND NON-INTEGRATED SYSTEMS
Capstone Project
Bengisu Özer,
Berfu Arslan,
Mücahit Şahin
Advisor: Prof. Dr. Mustafa Özbayrak
İSTANBUL, 2018
T.C.
BAHÇEŞEHİR UNIVERSITY
FACULTY OF ENGINEERING
DEPARTMENT OF INDUSTRIAL ENGINEERING
Name of the project: A Framework for The Generic Implementation of Industry 4.0 Into Non-­‐‑
Automated and Non-­‐‑integrated Systems Name/Last Name of the Student: Bengisu Özer/Berfu Arslan/Mücahit Şahin
Date of Project Defense: ….. /….../……
I/We hereby state that the capstone project prepared by Bengisu Özer/Berfu Arslan/Mücahit Şahin has been completed under my/our supervision. I accept this work as a “Capstone
Project”.
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Prof. Dr. Mustafa Özbayrak I hereby state that I have examined this capstone project by Bengisu Özer/Berfu Arslan/Mücahit Şahin which is accepted by his supervisor. This work is acceptable as a
capstone project and the student is eligible to take the capstone project examination.
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Doç. Dr Ahmet Beşkese Head of the Department of
Industrial Engineering
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Academic Honesty Pledge
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1
ABSTRACT
A FRAMEWORK FOR THE GENERIC IMPLEMENTATION OF INDUSTRY 4.0 INTO
NON-AUTOMATED AND NON-INTEGRATED SYSTEMS
Bengisu Özer, Berfu Arslan and Mücahir Şahin
Advisor: Mustafa Özbayrak
May, 2018, 32 Pages
In traditional systems, there are high margin of errors, low efficiency, and timing
problems, because of the lack of automation technology utilization. These shortcomings
lead to high costs and low profit margins and therefore, impair companies in financial
terms, since automation and industry 4.0 technologies are not applied to the systems, and
data management, which is one of the most consequential benefits of Industry 4.0, cannot
be utilized. In the traditional systems, the data are mostly kept manually, causing to enter
missing or incorrect data. Due to lack of cloud computing, there are also problems
concerning the storage of data collected, up-to-date tracking, sharing and accessibility.
This project will examine the integration of Industry 4.0 into traditional systems to address
these deficiencies and to avoid errors, and will take advantage of Industry 4.0. The project
aims to discuss the applicability of industry 4.0 to traditional systems and create a
framework of making traditional system more effective by applying technological
developments such as CPS, cloud computing, intelligent devices which are the benefits of
Industry 4.0.
In this study, a roadmap for implementation of Industry 4.0 to traditional systems and the
advantages of Industry 4.0 will be presented. Nevertheless, it is complicated to set a
roadmap for all processes. Accordingly, this paper will focus on manufacturing processes
and environment. This paper is expected to become a guideline for the implementation of
Industry 4.0 to manufacturing systems and lead to apply technology to manufacturing
environment and service to minimize errors with the help of intelligent systems.
Key Words: Automation, Cloud Computing, CPS, Industry 4.0, Intelligent Systems, IoT,
Manufacturing Systems
2
TABLE OF CONTENTS
Academic Honesty Pledge ..................................................................................................... 1 ABSTRACT........................................................................................................................... 2 TABLE OF CONTENTS....................................................................................................... 3 LIST OF FIGURES ............................................................................................................... 5 LIST OF ABBREVIATIONS ................................................................................................ 6 Chapter 1 Introduction ........................................................................................................... 7 Chapter 2 Background of Industry 4.0 ................................................................................... 9 2.1 Introduction ............................................................................................................. 9 2.2 Industry 4.0 ........................................................................................................... 10 2.3 Industrial Revolution History ............................................................................... 10 2.4 Industry 4.0 Components ...................................................................................... 11 2.5 What is the difference of Industry 4.0 than before?.............................................. 15 2.6.1 Industry 4.0 Tools .............................................................................................. 16 2.7 How to integrate industry 4.0 into non-integrated systems?................................. 16 2.8 Differences between traditional and future factories? .......................................... 17 2.8.1 Smart Factories ............................................................................................ 17 2.8.2 Digital Factories ........................................................................................... 17 18 Chapter 3 Literature Review ................................................................................................ 19 Chapter 4 Roadmap.............................................................................................................. 24 4.1 Introduction .................................................................................................................... 24 4.2 The Aim and the Objectives of the Research................................................................. 24 4.3 The Benefits and Challenges of Industry 4.0 Systems .................................................. 25 4.4 Research Framework ..................................................................................................... 26 4.5 The Roadmap for Implementation of Industry 4.0 into Non-integrated Manufacturing
Systems ....................................................................................................................... 26 4.5.1 Introduction ........................................................................................................ 26 4.5.2 ROADMAP ....................................................................................................... 26 4.6 The Benefits of Integration of Industry 4.0 into Manufacturing Area ........................... 29 Chapter 5 Conclusion........................................................................................................... 30 3
REFERENCES .................................................................................................................... 32 4
LIST OF FIGURES
Figure 1: Industrial Revolution History ................................................................... 10 Figure 2: Internet of Things ..................................................................................... 11 Figure 3: Cyber Physical Systems ........................................................................... 12 Figure 4: Cyber Physical Systems Diagram ........................................................... 13 Figure 5: Big Data ................................................................................................... 13 Figure 6: Smart Industry .......................................................................................... 18 5
LIST OF ABBREVIATIONS
AI Artificial Intelligence BDA Big Data Analytics CPS Cyber Physical System ICT Information Communication Technology IoT Internet of Things IT Information Technology IWN Internet Wireless Network LAN Local Area Network M2M Machine to Machine RAMI Reference Architecture Model Industry RFID Radio-­Frequency Identification TPS Toyota Production System VEF Virtual Engineering Factory VEO Virtual Engineering Objects VEP Virtual Engineering Process 6
Chapter 1 Introduction
Increasing global fierce competition among the companies as well as the states, force the
organizations to search for better technologies to enable them to supply products to their
customers in better quality with a more competitive price and in a shortest possible time.
Especially newly industrialized countries such as China, Taiwan, South Korea and other
Asian countries have joined this competition first with low labor cost, and then later with
high quality technological products and in many aspects, surpass the western organizations
in several sectors.
Western organizations, in order to compete with the newly developed competitors, have
long been struggling to catch their competitors and working hard to be forefront again.
The recent developments in especially electronic and computer technologies enable the
many processes or issues possible now, which were either impractical or too costly to do
before.
The Industry 4.0 concept, which first was introduced at the Hannover Fair in 2011, named
as the 4th Industrial Revolution especially by German scientists, concerns the
developments towards the unmanned systems originating from the blending of computer,
electronic and mechanical engineering technologies with production throughout the value
chain.
Since the concept of Industry 4.0 is relatively very new, many engineering organizations
assume that introducing a high-level automation into shop floor would enable Industry 4.0
into the organization. However, Industry 4.0 is much more than introducing a high-level
automation and it is rather concerned with the entire value chain and treat the entire value
chain as a single body with a very high level interconnection enabling an uninterrupted
material, information and finance flow between the organizations that form the value
chain.
The aim of this research is to create a roadmap for the engineering organizations that plan
to move towards Industry 4.0. This study provides a framework for the people that prepare
the current organization for becoming an organization that implements Industry 4.0.
7
Industry 4.0 concerns using different technologies such as computer science, electronics,
mechanical engineering, mechatronics and industrial engineering and a very strong
coordination is needed to bring these rather different technologies together and work in
synchronization. Therefore, a roadmap is a must for this rather very complicated journey
towards the Industry 4.0.
We developed such a roadmap for the newly established teams to help them in their
mission towards Industry 4.0.
This thesis consists of 5 chapters. In the light of this introduction, the content of the thesis
has been created as follows.
In the first chapter, the thesis is introduced and the basic information about Industry 4.0
and importance of the value chain for a company and manufacturing is presented. This
enables readers to form an opinion about the content of the thesis.
The chapter two provides relatively a rich background for the people who has little or no
knowledge in Industry 4.0.
Chapter three presents the literature published in this area. The papers we reviewed were
collected among the pioneering research works that give a solid foundation for the subject
and provides a useful direction for the people who are willing to develop a research agenda
in the field.
In chapter four, a step by step roadmap for Industry 4.0 integration to the entire value chain
is presented.
The last chapter, which is chapter 5 presents the conclusions drawn and the lessons learned
from the study conducted in this research.
8
Chapter 2 Background of Industry 4.0
2.1 Introduction
Social, economic, environmental and technological developments are creating obstacles for
manufacturing companies. New and more sophisticated competencies are required to
follow and react to these improvements, and manage the value chain. These needs can be
met by virtual and physical structures. They ensure that the entire product life cycle is
integrated to each other and more flexible. The integration of automation and intelligent
technologies into systems increases product quality and process efficiency. In order to
make the best use of all these developments, they have to be applied to the entire value
chain together with the manufacturing system (Schumacher et al., 2016).
Intelligent manufacturing is a modern manufacturing concept which originates with
intelligent science and developing technology. Interchanging data among products and
manufacturing optimization with the help of improving technologies are the considerations
of intelligent manufacturing. It advances the product life cycle entirely, in the whole
processes of a product. The products of thriving technology such as sensors, smart devices
and data analytics, can be utilized to pave the way of the whole life cycle of a product.
Intelligent manufacturing enhances the product quality and production efficiency, and it
also increases the service level. Aptitude of confrontation with the changes of the global
market advances the competitive power of a manufacturing company (Zhoung et al.,
2017).
Factory is one of the four important features to be completed in order to ensure the future
vision of manufacturing. The future factory vision is called smart factory which is essential
for Industry 4.0. Smart factory allows the sources to interoperate and share data with each
other, make predictions, sustain the machines in the factory, and ensure the functionality of
the operations. Moreover, manufacturing processes can be simulated and interlocked, and
also managed independently, through smart factories (Qin et al., 2016).
This paper explains Industry 4.0 concept and its historical development process.
Additionally, knowledge about the components and smart factory vision of Industry 4.0
can be obtained in this paper.
9
2.2 Industry 4.0
Industry 4.0 is first entitled in 2011 in Germany to express the development goals of
German manufacturing industry. The term aims to integrate industry with developing
technology. Advancing more efficient, profitable and energy-saving equipment and
combining it with smart software systems to drive equipment. Smart software systems also
allow devices to connect each other and reach each other’s data. This connection is
denominated as internet of things (IoT) and this feature provides intelligence to equipment
since it can operate without human guidance.1
2.3 Industrial Revolution History
Figure 1: Industrial Revolution Historyi
In the late 18th century, water and steam power are started to use in mechanical production
and manufacturing industry gained momentum through these improvements. This period
has started in the United Kingdom and named as the 1st Industrial Revolution. In the
ensuing period, the lack of the new industry with regard to meet the needs of the market
has increased the requirement for revival. Thus, the 2nd Industrial Revolution was
actualized in the 19th century. With this revolution, the usage of mass production, electrical
and assembly lines became widespread. With the rapid developments in technology in the
1
http://makina.dpu.edu.tr/index/slide/2691/endustri-40-nedir
10
20th century, technological devices and information systems have been begun to utilize in
the industry and these improvements brought about the 3rd Industrial Revolution. In this
respect, the 20th century integrated production and automation. Today, technology
continues to evolve, and machines are becoming fully automatic and digital, therefore the
4th Industrial Revolution comes out. Unlike Industry 3.0, machines of the fourth industrial
revolution are not only programmable, but they can also collect and analyze data and
operate without human collaboration. These advancements in technology are leading to
smart factories of today and tomorrow. 2
2.4 Industry 4.0 Components
The components that enable the emergence of Industry 4.0 are listed below. These
components both enable the emergence of the Industry 4.0 and the concept to operate at
full efficiency.
2.4.1 Internet of Things: This can be understood as the network of physical objects. It
enables objects connect each other and get access to each other’s data and analyze them
without human intervention. With developing technology, internet of things is applied
everywhere physical objects exist.
Figure 2: Internet of Thingsii
2
https://www.cleverism.com/industry-4-0/
11
2.4.2 Artificial Intelligence (AI): The aim of artificial intelligence is the build machines
and computer programs which can teach themselves without the need of program and
make decision by their selves. 3
2.4.3 Cyber-Physical Systems (CPS): These systems aim to connect virtual and physical
worlds. Within the context, it builds smart factories. CPS enable to communicate, monitor
and control the system with the help of sensors and other IoT providers.
Figure 3: Cyber Physical Systemsiii
3
Wissen Academy, Lecture Notes
12
Figure 4: Cyber Physical Systems Diagram iv
2.4.4 Internet of Services: Internet of Services are considered as the objective of internet
of things. Internet of Services provide remote control and services by using IoT devices.
2.4.5 Big Data: There has been a significant increase in terms of the amount and variety of
data collected as a result of the widespread use of technological tools in daily life and work
places. But the important aspect here is not the amount of data collected, but how the data
are protected, analyzed and used. Consequently, the utilization of big data can be provided
by integrating them into decision-making and learning mechanisms.
Figure 5: Big Data v
2.4.6 Cloud: Cloud is an internet based service that allows the data to be used and shared
when requested. In this way, the data can be accessed and stored on the internet. It also has
access and integration to multiple platforms and advanced security systems.
13
2.4.7 Machine to Machine (M2M): It is a technology which allows machines and other
technological devices get in contact and share data with each other without physical
interaction and human activity.
2.4.8 Virtualization: It is the use and processing of the collected physical data in the
virtual environment by the operating systems.
2.4.9 3D Printing: The realization of shapes found as digital data. In addition, it produces
complex geometries which standard manufacturing processes cannot perform.
2.4.10 Smart Products: The objects that have the ability to process data through physical
and software interfaces. These interfaces support regular data transfer from product to
manufacturer and user.
2.4.11 Reference Architecture Model Industry 4.0: The standardization work that
integrates the production stages to the automation pyramid to create a solution area for
Industry 4.0.
2.4.12 Information Communication Technology (ICT): The term identifies the devices
and applications which ensure the combination, information access and data sharing of
people and organizations. It is generally used as a synonym of Information Technology
(IT). However, ICT considers telecommunication technologies, particularly.
2.4.13 Internet of People: This is the approach where individuals and their devices are
considered as the components of internet, but not only as the consumers of it.4
2.4.14 Industrial Internet: Industrial Internet is the internet which used by the equipment
in production system to generate more data, generate data, optimize and anticipate
problems that may arise.
2.4.15 Smart manufacturing: It is a process where automation systems are used to
manage manufacturing processes more effectively and increase manufacturing efficiency.
2.4.16 Sensors: The sensors sense the data in the physical environment and transfer the
data to the digital form that the computers can use.
4
https://www.sciencedirect.com/science/article/pii/S1574119217303723
14
2.4.17 Local Area Network: Network structure that connects the existing computers and
related devices to a single network with common language via line or wireless systems in a
certain area.
2.5 What is the difference of Industry 4.0 than before?
The reason why the industry 4.0 is called a new industrial revolution is that it is
different from the previous stages in terms of human activity. At this stage, the
machines and technological equipment can operate completely independently from
the human activity and they can manage, control and maintain themselves with the
help of sensors, RFID systems and other IoT provider devices. At this stage, the
machines do not need to be managed by humans, anymore. Therefore, the machines
have developed their characteristics of learnability and become able to teach
themselves.5
The most significant difference of Industry 4.0 than before is the capability of
connection of components as well as the companies in the value chain. Industry 4.0
ensures common data base structure for entire value chain. The connection is
provided through LAN which connects all devices to a single network and provides
management via a single channel. Without LAN, it is not possible to access required
data, therefore LAN is an essential component of Industry 4.0. This connection
provided through LAN enables distance-access for all users and integration of
devices.
2.6 Aims of Industry 4.0
Industry 4.0 aims to automatize all processes in a factory such manufacturing.
By this means, the need for human power is reduced so that errors originating from human
are minimized. Since the learning and operation perfection times of robots are shorter than
humans, the principle of zero defect in production becomes applicable, high quality
production standards can be followed and time saving is possible. Automated systems
provide cost savings and profitability in the long-term. In addition, these systems are more
compact, providing opportunity to work in smaller facilities.
5
https://www.quora.com/What-is-the-main-difference-between-Industry-3-0-and-Industry-4-0
15
Continuous data collection and analysis is performed in systems where Industry 4.0 is
applied. Thus, continuous control and corrective actions are taken when necessary. In
addition, these systems have the ability to make decisions through the data analyzed when
needed.
Moreover, it has the ability to share the collected and analyzed data via internet with the
desired receivers and among machines (m2m), which provides continuous and regular data
flow.
With the integration of Industry 4.0, sensors and other automated systems help people
work more efficiently, safely and comfortably. In this way, employees are saved from the
adverse impacts of the environment.
2.6.1 Industry 4.0 Tools
o Sensors
o Servers - IT
o Barcode
o RFID
o Conveyor Systems - Robots
o Machines
2.7 How to integrate industry 4.0 into non-integrated systems?
Industry 4.0 can be a concept which aims to transfer traditional manufacturing techniques
to digital methods to improve production efficiency and flexibility, product life cycle and
quality.
Thriving science and intelligent technologies are the fundamentals of industry 4.0 which
ensures the developments in every step of a product life cycle. By utilizing several
intelligent devices such as smart sensors, adaptive decision-making models, advanced
materials, and data analytics, product life cycle and product characteristics can be
enhanced. (R.Y. Zhong et al., 2017, p. 618)
Emerging smart factories to generate smart processes and products is the one of the most
essential considerations of Industry 4.0 in terms of manufacturing approach. Smart
factories enable digitalization in manufacturing and take advantages of intelligent solutions
16
and flexible processes. Intelligent solutions provide continuous communication between
resources by this means, production efficiency enhances and complicated market demands
can be met. (A. C. Pereira et al., 2017, p.1209)
2.8 Differences between traditional and future factories?
The traditional factory system is based on human power. Production elements such as
warehouses, cranes, machines and robots operate under the supervision of people. Any
failure in one of these processes causes both time and financial loss. Factories, sensors and
automation systems has begun to evolve along with Industry 4.0. One of the consequences
of these developments is the emergence of digital factories as well as smart factories.
2.8.1 Smart Factories
The new factory model, in which the machines communicate with each other and supervise
the production system themselves. Controls made on the machine side, minimize the error
rates and waiting times that can occur during production processes such as production,
quality control and maintenance. Thus, maximum efficiency is obtained from production.
Smart factories should be supported with smart products that can continue communication
after production. These products ensure that all relevant data is stored for future prospects
in an intelligent system. Thus, continuity of communication with the factory is ensured in
cases such as deterioration of products, change of parts, maintenance and repair. The fact
that factories and product models are in constant contact with each other reveals the
concept of Big data which are called 'today's oil' by companies. Regular communication
ensures that more accurate analysis and more accurate report are being prepared with the
serious amount of data collected.
2.8.2 Digital Factories
One of the new factory models that come to the fore is the digital factory. In fact, we can
call these factories virtual factories. Before the factory is actually set up, the factory-related
data are evaluated in computerized simulations. If we need to open up this data in detail,
we can say production schedules, maintenance and repair planning, productivity and
profitability. As a result, when the plant is not physically constructed, all possible
disruptions are calculated and eliminated in the virtual environment. Digital factories are
actively involved not only in the virtual environment but also after the physical factory
17
construction. These factories offer a wide range of hardware and software that allows the
flow of data to be maintained. With the integration of digitalization into production, 3D
printers, robots and production services have emerged. At this point production has
become more flexible, fewer production quantities are possible, fewer and more qualified
employees.
The main benefits of Digital Factories:
·
The space required for the factory is reduced,
·
Rapid changes,
·
Decrease in risk,
·
Observation in the virtual environment,
·
Saving on time,
·
Optimization of production equipment.6
Figure 6: Smart Industryvi
6
http://www.hurriyet.com.tr/endustri-4-0-ve-akilli-fabrikalar-40234176
18
Chapter 3 Literature Review
Brettel et al. (2014) have studied the influences of decentralization, virtualization and
network construction on manufacturing systems’ performances. They emphasized the
effects of the high labor costs in German companies for the global competition and they
indicated
that
German
companies
cannot
compete
with
the
international
companies with only low labor cost and high quality products on standard products. They
argued that the mass customization is the way of meeting the varying customer needs by
utilizing from economies of scale and decreasing time to market. Virtualization of supply
chain allows companies to reach real-time data and get information about the related
product or process. The concept of Cyber Physical Systems (CPS) is provided through
internet, which enables communication between people and machines. CPS allows data
sharing and analysis, and ensures independent decision making mechanisms. Thus, smart
products can decide their own processes, which can be termed as self-control. CPS
provides monitoring and control in every step and could benefit from mass customization.
The products and processes can be managed digitally through the increased utilization of
information and through data sharing. Thus, decentralized units can be innovated rapidly,
using the modular modelling and simulation techniques.
According to Pereria and Romero (2017), increased productivity is the essence of the
industrial revolution and Industry 4.0 developed after three industry revolutions by the
thriving technology. With Industry 4.0, intelligent systems that are able to transfer
information independently, and manage their actions, started to being used in industry. The
fundamental aim of Industry 4.0 is to analyze the vision of manufacturing by production
paradigm. This paradigm would ensure significant benefits for organizations in relation to
product-service, new business models, market economy, business environment and skills
development. Their purpose of writing this article to provide comprehensive information
about the methodology of Industry 4.0. The content of the article is the analysis of the
effects of the paradigm, and the economic and social consequences of it.
Stock et al. (2016) discussed the opportunities in Industry 4.0 for a sustainable
manufacturing. They approached to the problem as a requirement, because of the
19
continuous and increasing demand to the consuming goods and capital. Industry 4.0
provides several opportunities for a sustainable environment and manufacturing.
Smart factories with sensors, RFID and QR codes, and other intelligent devices are
essential for Industry 4.0, and they can share and manage their data. With these advantages
of Industry 4.0, intelligent resource allocation and product processing by smart products
can be executed, and this creates a more efficient and sustainable company, therefore an
industry.
According to Shafiq et al., (2016) rapid development in the field of manufacturing posed
several requirements to industry, such as transferring data instantaneously and quickly.
Thus, Industry 4.0 and smart factory concept have emerged. The purpose of these smart
factories is providing stability, utilization of resources efficiency, ergonomics and
especially customer integration to processes. They also focused on three basic concepts
which ease the application of Cyber-Physical System (CPS) on manufacturing
environment. These concepts are Virtual Engineering Factory (VEF), which focuses on
factory, Virtual Engineering Process (VEP), which focuses on process, and Virtual
Engineering Object (VEO), which focuses on resources. In general, they created a virtual
factory with the help of these concepts, which increases accuracy of industry 4.0 on
manufacturing.
Wagner et al. (2017) aimed to introduce a smart factory system based on Internet of Things
and Internet of Service, which are the essential components of Industry 4.0. They also
discussed the advantages of the integration of Industry 4.0 into lean manufacturing
environment. By the integration of Industry 4.0 into lean manufacturing environment, lean
principles are supported and stabilized. These integrations can be easily designed and
developed with the Industry 4.0 impact matrix. The use of cyber-physical just-in-time
delivery applications could be considered as an example for lean process technologies
based on improvements in these effects of matrices. By utilizing Industry 4.0 matrices, a
more sustainable manufacturing environment is possible.
De Sousa Jabbour et al. (2018) focused on Industry 4.0 and environmentally-sustainable
manufacturing, which can combine production and consumption. They offered an insight
20
into the contribution of Industry 4.0 to ensure environmentally-sustainable manufacturing.
According to the study, achievement of sustainable manufacturing with the support of
Industry 4.0 technologies helps ecological and economical improvement of a company,
thus a country. They also discussed critical success factors to comprehend the interaction
of Industry 4.0 and environmentally sustainable manufacturing. These can be considered
the essential activities of a company to compete and be successful in the market.
According to Wang et al. (2015), with the widespread of IoT and smart services
technologies, machines are able to connect with each other through Internet Wireless
Network (IWN). This improvement lead to change data flowing and self-organizational
interaction between machines. The authors listed three types of integration systems used
for implementing industry 4.0: vertical integration, horizontal integration and end-to-end
integration. The authors focused on vertical integration which is the coordination blocks
that are implemented on the cloud and based on big data analytics systems. Also, they
compared traditional factories and smart factories based on their technical features.
Schumacher et al. (2016) introduced the development of the manufacturing companies in
relation to the Industry 4.0 vision. According to the study, companies need virtual and
physical structures to execute transition from existing systems to next generation
production systems. Concepts such as IoT, Industrial Internet, Cloud-based Manufacturing
and Smart Production can be a partial solution for the needs. The practical purpose of the
study is to design an analysis model to understand how Industry 4.0 is integrated into a
company, whether it responds to the company strategy and its appropriateness.
Zhoung et al. (2017) studied intelligent manufacturing as the contribution of Industry 4.0
to industry. They explained the impacts of Industry 4.0 to manufacturing systems, and it
enhanced the product quality and production processes. Additionally, they concerned
Industry 4.0 implementations shorten time to market and create an intelligent environment
by the help of smart objects, which has the ability to comprehend and behave. They
introduced artificial intelligence, internet of things, Cyber-Physical Systems (CPS), Cloud
Computing, Information and Communication Technology (ICT), and Big Data Analytics
(BDA) in terms of intelligent objects. Moreover, they briefly clarify the strategic plans of
21
governments and major international companies in the European Union, United States,
Japan, and China about intelligent manufacturing. They talked about future perspectives
with regard to human-machine cooperation, application of intelligent manufacturing and
data-driven intelligent manufacturing models.
According to Fatorachian and Kazemi (2018), increasing demand and producing
innovative products necessitated the emergence of a new manufacturing systems, which is
called industry 4.0. They created an effective framework which makes easy to integrate
internet of things (IOT) and cyber-physical systems (CPS) on traditional manufacturing
system for originating smart factory. They also mentioned enablers and drivers of Industry
4.0 in the integration processes of smart factories. Consequently, they have created a
framework by integrating internet of things (IOT) and cyber-physical systems (CPS) into a
factory which is work with traditional systems and turn it into a smart factory which it
works based on Industry 4.0.
Bortolini et al. (2017) examined the effects of Industry 4.0 principles on the new
generation assembly lines. Classic assembly lines are not qualified enough for today's
industry. Industrial technologies have rapidly developed and market demands have
radically changed with the introduction of the first assembly line. After the integration of
Industry 4.0, mass production got replaced by individual production by means of
intelligent sensors connected to the internet and each other. This change has improved
customer satisfaction, product quality and production efficiency.
According to Liao et al (2017), in recent years, industry 4.0 has become fashionable
between governments’ manufacturing policies, academic researches. The purpose of this
academic study is to analyze the research, which has been done since the beginning of
Industry 4.0 concept and based on these research, they developed a future perspective.
They focused on four main categories to analyze the researches in detail. These four
categories are the concrete features of Industry 4.0 which are the people who work on
Industry 4.0, main research directions, the current research efforts and existing Industry 4.0
application fields. Consequently, this study submitted a systematic literature review based
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of Industry 4.0 from past to future, also referred journals and popular conferences for the
field of Industry 4.0 and key features of Industry 4.0, systematically.
Qin et al. (2016) introduced Industry 4.0 essentials and present manufacturing systems.
According to the authors, Industry 4.0 needs a long period of time to thrive in industry
properly and provide four aspects which are factory, business, customer and product, to
satisfy future manufacturing visions. They discussed the differences between the present
systems and Industry 4.0. The study also describes a framework for Industry 4.0 in the
present manufacturing systems, and concludes that the present systems are evolving in the
guidance of Industry 4.0.
According to Zezulka et al. (2016), technological revolution was a requirement in the
earlier stages of Industry 4.0, but nowadays, comprehending the current system is more
important than the technological revolutions. With Industry 4.0, human activities have
been connected to numerous communication systems. In virtue of the connection,
boundaries of communication were left through the systems used in facilities. These
systems could be listed as IoT, IoS and IoP. In this article, the authors referred to RAMI
4.0 which is a subcomponent of Industry 4.0, as the most important system model.
Trensjak and Cosic (2017) emphasized the potentiality of developing fully automated
processes. According to them, with Industry 4.0, the stereotyped professions would change
and people would have to use advanced technological tools. The result of the integration of
Industry 4.0, human effect would be removed from the production processes, thus
virtualization settle in production. Virtualization would be supported by cloud system in
the aggregation and analysis of more data in a shorter period of time. The active use of
cloud system would increase the need for new types of data-gathering products, named as
‘Smart Products'. Smart products manage process planning, operation sequence and
coordination of planning. Additionally, this study examined what mathematical models and
algorithms are required, while switching between virtual and existing systems.
According to Yin et al. (2017), the supply-demand relationship of the customers has
changed a lot from Industry 1.0 to Industry 4.0. Industry 1.0 focused on human activities
and agriculture, whereas Industry 2.0 focused on technological devices (electricity,
23
electronics and mechanical parts). Industry 3.0 brought innovations such as analogue
to digital converter systems and now, Industry 4.0 provides connection and flow between
all manufacturing systems through the Internet of Things (IOT), Cloud, Cyber-Physical
Systems (CPS) and Big Data. This study emphasized the evaluation of supply-demand
relationship based on industrial production systems, such as supply, job shop, cells, seru
principles and Toyota Production System (TPS). Also, they analyzed the differences of
seru principles, TPS and cells based on strategy, operations, technique and performance.
Chapter 4 Roadmap
4.1 Introduction
Industry 4.0 prepares the way for efficient value chain processes through accurate data
management and processing, and automation systems. Integrating Industry 4.0 concept to
traditional manufacturing systems enhances resource utilization particularly time, material
and labor, and increases the performance of the system as a result of intelligent automated
systems and error-free data sharing and analysis.
This chapter presents a complete roadmap for implementation of Industry 4.0 into nonautomated, non-integrated manufacturing systems and guides how to best utilize from
Industry 4.0 in the manufacturing area.
4.2 The Aim and the Objectives of the Research
The research aims to provide an elaborative roadmap that is beneficial for organizations in
the meaning of understanding the Industry 4.0 aims and benefits, and also application of
Industry 4.0 into the traditional manufacturing systems.
The thesis answers three basic questions: What is the context of Industry 4.0 that is applied
to the system? How to integrate these to non-integrated and non-automated systems? What
level of transformation is required to achieve a fully functional Industry 4.0 in the system?
Thus, it discusses the required infrastructure for an Industry 4.0 implemented system and
then, it provides the roadmap to transform the available non-automated and non-integrated
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system into fully functional Industry 4.0 applicable system. This roadmap is a guide for the
design engineers to transform the traditional systems to fully automated systems by
explaining step by step integration of Industry 4.0.
4.3 The Benefits and Challenges of Industry 4.0 Systems
Integration of Industry 4.0 have some benefits and challenges in systems. It is crucial to
address these benefits and challenges in order to understand the implications of Industry
4.0.
Future production systems will be network-based, which is the intersection of the real and
virtual worlds. With Industry 4.0, the stereotyped production systems have changed. All
automation systems, robot integration of production, digitalization, communication
between cloud technology and the internet of things and the machines are designed to
provide the most efficient production continuity. The fact that Industry 4 in the production
areas finds more application areas for itself has increased the productivity in the process
seriously. Product and information integrity provide a great advantage in the easy
collection and analysis of data, so high-performance production systems will be developed.
Industry 4 does not have a definite pattern, so it can be integrated into any production
system. With Industry 4, the previously mentioned factory models of smart and intelligent
are coming out. This factory models give us flexible production possibilities. To explain
flexible production; this system is to easily be adapted the manufactured products to
changing product options and techniques. Unlike elder production systems, Industry 4
must be based on the integrity of products and information. It is important not only to
produce, but also to make smart production by using IOT and cyber-physical system.
In short, production will be more secure and technological, so the costs will decrease in
this direction and the duration of use of the produced products will be longer. Of course,
this transition cannot take place very easily. The point is to consider the risks that may be
in the period of integration of companies that want to realize this revolution. While
Industry 4.0 offers low costs in the long run, companies will have to make significant
investment costs in the transition period. In fact, these costs are not limited to the transition
period. Any technical disruption that may occur in this system based on automation can
25
lead to overhead costs. Therefore, the economic situation of companies must be capable of
meeting these costs.
4.4 Research Framework
It is possible to integrate industry 4.0 into a wide area from production to service. Our goal
in this study is to take a more in-depth analysis of the limited application area by
considering Industry 4.0 application in a production system environment. While doing this
research, the academic articles and interviews related to the topic, and integrated system
examples are utilized.
4.5 The Roadmap for Implementation of Industry 4.0 into Non-integrated
Manufacturing Systems
4.5.1 Introduction
There are four main components that create a production system and affect the efficiency
of the system. These elements can be entitled as information technology, management,
physical systems and human resources. To be able to effectively utilize from Industry 4.0
in production systems, the systems need to be integrated by these components.
4.5.2 ROADMAP
Company Based Structure
0. Current Situation Analysis
In this section, companies should identify their current capabilities and advancements in
terms of Industry 4.0 components. Not all companies have the same level of integration of
Industry 4.0 systems, so each company should follow unique implementation structure. For
instance, a company might have already integrated automatic systems to its facilities but
the required technology for data transformation among these systems might be deficient. In
such a case, the company could start following the roadmap from the second step, which
gives instructions about connection via LAN based on IoT.
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1. Automatic systems’ integration
As the first step, a system can be called as an Industry 4.0 integrated system, when it is
compatible with Industry 4.0 components. Utilizing these components such as RFID
systems, sensors, robots and handling systems have an enormous importance to enable the
system automation. With these components, the connection in the value chain is provided.
2. Connection via LAN based on IoT
When a system is automated, one of the most important aspects is to connect the
production elements to each other via internet. Many protocols have been set up to ensure a
smooth and continuous flow of data between these devices. Thus, through the ongoing
connection in the production lines, the production elements have all kinds of knowledge to
make decisions by data transfer.
3. Data Sharing and Gathering via Cloud Systems
Data gathering and sharing are two important elements of Industry 4.0 benefits for
continuity and quality in production systems. Numerous data from related devices are
collected to a common system, which is called as Cloud, so that each device sense others’.
It supports the elimination of any incompleteness and inaccuracies in the data through
utilizing continuous data flow and constant connection. Also, Cloud provides the best
platform for Big Data with its enormous storage capacity. Cloud provides a Relational
Database Management System, which allows companies to share data with their suppliers
and customer companies. Thus, data is accessible in a broader scope. It also guarantees
accurate process planning and task distribution. Data gathering also improves prediction
capability of companies.
4. Data Analysis, Decision Making and Control
The intelligence of Industry 4.0 arises from not only its ability to collect and but also
analyze data. Through analyzed data, intelligent systems have the ability to control the
current situation of system and make decision according to analysis result.
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5. Cyber Security
With Industry 4.0 applications, systems have continuous connection with Internet. This
connection makes the system vulnerable to any cyber-attack that can be performed via
Internet. To prevent these attacks, companies need to pay attention to cyber security losses
and apply cyber security practices.
6. Value Chain Structure
To ensure effective process planning, all companies in the value chain must share their
data with each other and this is provided by Relational Database Management System. So,
each company in the value chain is continuously updated about the requirements and
timing. Thus, companies can make the necessary arrangements in their business plans. Due
to the fact that required data are always available in the system, all companies should take
the responsibility of protecting the data and concern the cyber security principals.
The basic elements of the value chain of a company:
1. Suppliers
2. Customers
3. Outsources
4. Logistics
For an accurate Industry 4.0 integration, continuous and mutual data flow must be
provided in Value Chain. For instance, company must organize the production plan
according to the orders of customer. The producer company must also provide the
necessary equipment and raw material from its supplier according to this plan. To do so,
the production plans and orders must be accessible among the companies in the value
chain. To ensure full availability of the Industry 4.0, all the elements in the value chain
must share the necessary information with each other. This could be actualized through,
the use of a common data base system in the value chain and continuous follow of each
other. Industry 4.0 enables the operations between all partners of value chain. It ensures
the companies to work as a single body and enhances the synchronization.
28
At this point, manual information could be eliminated and communication traffic is
prevented. Through this, full and timely procurement, transportation and production are
ensured. Additionally, the use of common data base requires security precautions. To
ensure the security, the system must be continuously monitored and the movements of
accessors are kept a log. The monitoring system can also prevent the access of people to
the database under threat.
4.6 The Benefits of Integration of Industry 4.0 into Manufacturing Area
There are several benefits of Industry 4.0 into manufacturing systems. The primary
benefits are listed above:
● Product improvement
● Enhances operation duration
● Continuous Tracking and Control
● Continuous Access of Responsible
● Shorter learning curves of labors through utilization of Virtual Reality (VR)
● More ergonomic working environment for labors via human motion tracking
sensors
● Ability to determine current customer needs and trends
● Flexible manufacturing
● Accurate product quality
● Eliminate waste cost and time by making use of virtualization tools
● Energy saving
● More transparent processes and relationships with continuous data sharing
● Conservation of resources
● Targeted planning processes
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Chapter 5 Conclusion
The developments in computer science and other engineering disciplines, now made the
whole world a single global market for the companies. In order to compete with the rest of
the global market, the companies in any sector must be now more agile, leaner, and must
produce highest quality products at a reasonable price and more importantly crafted
products aim to satisfy the customer requirements with a highest satisfaction.
However, reaching such a high-quality production with minimum cost, require a
manufacturing organization that is not only more agile and leaner but at the same time has
a strong interrelationship with the organizations that are in its value chain. This
interrelationship is not only having a well-synchronized material flow but rather having a
common database that are shared by all the partners in chain so that every single unit in the
value chain would be able act as a member of single body driven by the very same center
of command.
This requires a well-designed value chain that is supported with a high-level automation
and a strong infrastructure, which should make the entire system as a single body and each
member organization executing a special duty so that the entire body would act in
synchronization.
Industry 4.0 is the latest development for creating such a value chain with supporting the
entire chain with a highest level of automation using the computer science, electronics,
mechatronics, mechanical engineering, industrial engineering and management science
disciplines. However, Industry 4.0 is more than just equipping the organization with a
high-level automation but rather it is a philosophy that would transform the organizations
into rather a unit of a larger body of organizations which work together to reach the
common goal of the entire value chain.
Transformation of the current traditional engineering organizations into Industry 4.0 driven
organizations would not be achieved without a very clear and detailed roadmap. This
roadmap should give a clear guidance to the organizations so that they would be able to
understand and know where to start, what infrastructure is needed and how and when this
infrastructure should be introduced into the transformation process, what sort of
30
coordination and collaboration would be built with the other members of the value chain
and how all these be achieved.
This study has aimed to create such a roadmap for industry providing a clear guide for the
team designated to transform the current organization into Industry 4.0 driven
organization.
We have provided a clear roadmap what infrastructure is needed for the different parts of
the organization such as production processes, data collection, communication, material
and information flow, not only for an internal use but for a global use. This enables the
other organization within the same chain would easily communicate with the other
partnering organizations so that every organization would easily take their own position
not to interrupt the information, material and finance flow.
This study considers three dimensions of change that are of relevance in relation to
Industry 4.0: technological change, social change and change in the business paradigm. As
regards technological change, digitalization has been a major driver of changes throughout
the value chain, and while many businesses recognize the need to adjust, far fewer, are not
aware the fact that this change is the heart of the overall transformation. There are
significant challenges as costs and risks for firms as regards digital security in intellectual
property protection, personal data and privacy; design and operability of systems;
environmental protection and health and safety.
The other dimension is the hardware transformation which concerns using the high level
direct numerically control driven machinery which is capable of doing all the required
processes with a highest quality and equipment such as machine tools, robots, material
handling systems capable of doing all the handling operations with a human sense,
measuring, controlling and more importantly making decisions autonomously.
The third dimension is the intelligent decision making processes which use a highly
intelligent artificial intelligent driven autonomous agent which would make any decision
with a high precision and intelligence.
This study provides the methodology and guidance for such transformation of current
organizations into Industry 4.0 by providing a clear guidance for the engineering and alike
groups to transform their own organizations with minimum waste of time and money.
31
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Figure References
i
https://www.simio.com/applications/industry-40/index.php
https://www.linkedin.com/pulse/internet-things-iot-prabhu- m/
iii
www.i-scoop.eu/industry-4-0/
iv
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v
https://blog.unbelievable-machine.com/en/what-is-big-data-definition-five-vs
vi
http://www.imm.dtu.dk/~jbjo/cps.html
ii
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