Industry 4.0 is a new way of organizing the means of production in order to turn traditional industry into a smart one. With greater adaptability to the needs and production processes in order to have a more efficient day, integrating new technologies that pave the way for the so-called fourth industrial revolution.
In addition to being a window to optimize times, industry 4.0 has as its key point the Internet of Things (IOT), which allows democratizing access to technology like never before. The IOT allowed to include this in medium and small companies, so that every corporation can access the technology.
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Fundamentals of industry 4.0
Given the evolution of the service industry, intelligent production systems were created that have the union of physical and digital technologies plus the integration of all stages of development of a product or process that brings greater efficiency and increased productivity. .
So that you can understand more clearly, we tell you four fundamentals and key points of industry 4.0:
- Instantaneous: we can see the monitoring and analysis of data in real time, guaranteeing greater assertiveness in decision-making. In the same way, know all the stages of the process and when they occur.
- Virtualization: this revolution proposes the monitoring of production processes to avoid failures and make the production network more efficient.
- Decentralization of decision-making: in order to improve production in the industry, the platform delivers information to people who, in a decentralized way, can make better decisions.
- Modules: it is clear that a production chain is divided into modules, therefore, a machine will produce according to demand or in the vast majority of cases with the request of the company, since it will only use the necessary resources to perform each task which guarantees the optimization of production and energy savings.
Get a free demo of the ibisa platform and start transforming and automating your company’s industrial processes.
Key points in industry 4.0
Data analysis and simulation Big Data: in industry 4.0 simulations analyze data in real time which allows reducing the physical and virtual world, so operators optimize and configure the machines for the next product on the virtual production line before an actual change.
Robotics: the use of robots is not something new, but in industry 4.0 it is possible to incorporate new capabilities into the process, managing to coordinate and automate a series of logistics and production tasks. In addition to reducing costs, these represent an increase in production.
IOT: they are different technologies that previously had no connection to each other, so industry 4.0 is the opportunity to interconnect with an IP-based network. This is one of the foundations of digital growth.
Cloud: this technological model allows the development of industry 4.0 to be sustained, since it requires the use of shared applications and data beyond the company’s servers.
3d printing: group of additive manufacturing technologies where a three-dimensional target is created by superimposing layers of material. This is a generally quick, cheap and easy way of manufacturing.
Augmented reality: the simulation and preview of processes is important to avoid errors or size relevant features. This industry 4.0 technology is compatible with different applications and services in different fields such as medicine, architecture, education and construction.
What is motivating companies to make the decision to join Industry 4.0?
In the document Industry 4.0: Building the digital enterprise, which is a survey with more than 2,000 participants from nine large industries and 26 countries that explores the benefits of digitizing companies, we find that:
- 35% expect to increase their income by more than 20% in the next five years
- 43% expect to lower costs by more than 20% in the next five years
- 56% expect to increase efficiency by more than 20% in the next five years.
This means that those involved have a positive expectation when starting with said implementation because, as we have mentioned before, industry 4.0 brings great advantages such as:
- Decreased maintenance costs
- Lower power consumption
- Unplanned time reduction
- Prediction of mechanical failures
- Greater engineering effectiveness with continuous monitoring
- remote collaboration
- Direct access to complete information
- Therefore, the expectations in cost reduction, increase in income and gain in terms of efficiency is a reality thanks to this new revolution.
In fact, according to PwC, the expected benefits from digitization for the next 5 years are:
- Additional income: 2.9% per year
- Cost reduction 3.6% per year
Get a free demo of the ibisa platform and start transforming and automating your company’s industrial processes.
Ibisa, platform for industry 4.0
Now that you are clear about how industry 4.0 works and its benefits, we want to show you how Ibisa managed to improve the processes of one of our clients.
Quala, a Colombian multinational of massive consumption dedicated to the production and commercialization of products (beverages, personal care, sweets, frozen and culinary).
They came to us in search of a specific solution to increase their productivity points through the improvement in operational efficiency (OEE), avoiding reprocessing since the data was extracted manually and then entered by people, which was generating errors. in several stages, both in capturing information and in subsequent transcription.
Therefore, unreliable and untimely data were being obtained for the efficient management of the production process in each of the plants.
By identifying this opportunity for improvement, Ibisa understood exactly what the requirement was and joint decisions were made to reduce activities without added value within the operation, reduce rework and optimize the time of those involved.
Within this stage, the client mentioned that it was essential for them to start with a pilot test, since this allowed them to analyze each modification and variable.
“Ibisa gave us the opportunity to have a quick implementation, and that we could improve it according to the process.” David Esteban Soler. Production process management leader.
It is worth mentioning that the main stakeholders are the leaders and the plant team, since they are the ones who are involved in this work every day. Therefore, we wanted to find out what the reaction of those involved has been to this new solution? to which they replied that:
“The operators really like it a lot, they think it is a very easy tool to use. And we feel that this issue of digital transformation transitions will always be very close to people…” David Esteban Soler, Production Process Management Leader.
We reduce rework!
Within this first stage of the pilot plan, Quala was able to identify certain internal aspects that needed to be improved in order to continue optimizing and improving each process, since it is important for them to have reliable, timely data and generate real-time alerts about the status of the machines to thus capitalizing at least four points of productivity in the plant, which is directly an immediate savings in the cost of transformation, which translates into producing more boxes with the same number of people as well as production times. Which aligns perfectly with business goals.
We managed to trust our data!
