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Industry 4.0 and Smart Factory

Alaa Khamis, PhD, SMIEEE

Head of Advanced Development Division at Sypron Solutions

http://www.alaakhamis.org/

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OUTLINE

What is Industry 4.0?

Why Industry 4.0?

Challenges

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WHAT IS INDUSTRY 4.0?

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WHAT IS INDUSTRY 4.0?

Source: Lev Grossman, “2045: The Year Man Becomes Immortal,” TIME Magazine, February, 2011.

• Human Scientific Progress

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WHAT IS INDUSTRY 4.0?

Agriculture revolution

Industrial revolution Light bulb Moon landing World Wide Web

Human Genome

Sequenced

8,0

00

yea

rs

120 years 90 years 22 years

9 y

ears

• The accelerating pace of change

Source: Lev Grossman, “2045: The Year Man Becomes Immortal,” TIME Magazine, February, 2011.

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Time to reach 100 Million customers

Telephone

75 Years

Web

7 Years

Facebook

4 Years

Instagram

2 Years

Pokemon Go

1 Month

WHAT IS INDUSTRY 4.0?

• The accelerating pace of change

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WHAT IS INDUSTRY 4.0?

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WHAT IS INDUSTRY 4.0?

Mechanization

Electrification

Automation

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Cost-efficiently

Qu

ick

ly

Flexibly

WHAT IS INDUSTRY 4.0?

Shorter lead time/product

life cycle

Larger product variance

For both large volume and small quantities

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WHAT IS INDUSTRY 4.0?

Digitalization Automation Connectivity Analytics

Source: B. Roland, "INDUSTRY 4.0: The new industrial revolution How Europe will succeed," Think Act, Tech. Report, 2014.

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WHAT IS INDUSTRY 4.0?

Emerging Cyber Physical System-based Automation

Classical 5-Layer Automation Architecture

ERP

MES

SCADA

PLC

Sensors-Actuators

Factory Operation Management Level

Process Control Level

Cell Level

Station Level

Machine Level

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• Global Market Size Forecast in 2019 (USD Billion)

WHAT IS INDUSTRY 4.0?

Smart Factory technology will have global market size of 74.80

Billion USD by 2022. [Markets & Markets]

293.57

115

62.98

29.53

15.255.3

0

50

100

150

200

250

300

IoT Big data Smart Factory Advanced Analytics Service Robotics Smart Machines

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WHY INDUSTRY 4.0?

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WHY INDUSTRY 4.0?

Better Quality

Increased Productivity

Sharing Economy

Improved Decision Making

Mass Customization

Faster Production

Industry 4.0

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WHY INDUSTRY 4.0?

Increased flexibility in production and manufacturing on demand

• Mass Customization

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WHY INDUSTRY 4.0?

Virtual modeling of manufacturing process

• Faster Production

Digital designs

Speed up the manufacturing

process :

Data-driven supply chains

120% in time needed to

deliver orders

70% in time to get

products to market

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WHY INDUSTRY 4.0?

• Better Quality

Siemens Smart factor for custom Programmable Logic Controls (PLCs)

500

120

100

200

300

400

500

600

1989 2015

Number of defects per million units

99.99% reliability rate

Top 100 European manufacturers could save

an estimated €160 billion in the costs of scrapping

or reworking defective products if they could

eliminate all defects.

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WHY INDUSTRY 4.0?

• Increased Productivity

Lights out/Dark factories work 24/7

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WHY INDUSTRY 4.0?

• Increased Productivity

Predictive maintenance

avoids machine failures on the

factory floor

50% decreased downtime

20% increased production

Predictive maintenance will

help companies save $630 Billion by 2025 [McKinsey]

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WHY INDUSTRY 4.0?

• Sharing Economy

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WHY INDUSTRY 4.0?

• Improved Decision Making

With access to factory and cross-market data, decision makers

can predict, response, and adaptto factory needs and market trends

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CHALLENGES

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CHALLENGES

General reluctance to change by stakeholders

Lack of adequate skill-sets

Unemployment

Communication reliability and QoS

Cyber security

Maturity of machine intelligence

Handling big data

Technical Challenges

Social Impact

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CHALLENGES

• Big Data

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CHALLENGES

• Big Data

RADAR: ~10-100 KB per second

SONAR: ~10-100KB per second

Camera: ~20-40 MB per second

LIDAR: ~10-70 MB per second

GPS: ~50 KB per second

Autonomous Vehicle

4 TB

Per Day

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CHALLENGES

• Social Impact

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CHALLENGES

• Social Impact

A study out of Oxford

University in 2014 found that

in the near future artificially

intelligent technology

could take over nearly

half of all U.S. jobs.

We can expect a wave of structural unemployment to spring

from the technology in the medium term.

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CHALLENGES

• Social Impact

Better inDull

Dangerous

Dirt

Dumb

Robots find applications in

“4D tasks”

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CHALLENGES

• Social Impact

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CHALLENGES

• Social Impact

Machine Human

Creative

Lower initial cost

and higher running

cost

Faster

More precise

Able to work in harsh environments

Higher initial cost and lower running

cost

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Thank you for your attention!

Questions?

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