What is industry 4.0? Smart manufacturing, data and automation

If you follow any manufacturing trends or news, you will have likely come across the term ‘industry 4.0’ already. It refers to the fourth industrial revolution, the current period that manufacturing and other industries are undergoing.

It is often used synonymously with terms like ‘smart industry’ and ‘intelligent manufacturing’, which reflect the ongoing digitalisation of manufacturing.

With the rise of industry 4.0, there is increasing pressure on UK manufacturers to embody its principles into their operations. By doing so effectively, plants should optimise their processes, overcome challenges and drive improved results.

This guide explains the concept of industry 4.0 in more detail, including what manufacturers can do to access the changes it promises to bring into their factories.

• What are the principles of industry 4.0?
• What are the benefits of implementing intelligent processes into your plant?
• How to introduce industry 4.0. into your plant

What are the principles of industry 4.0?

Industry 4.0 covers the entire manufacturing process, affecting the techniques, resources and equipment utilised from beginning to end. The term is used generally to describe increasing innovation, technology, and intelligence in the industry.

Examples of principles that fall under the ‘industry 4.0’ remit include:

• Digitalisation (including the use of artificial intelligence, augmented reality and robots)
• Interconnectivity between systems
• Bridging digital and physical spaces (such as through additive manufacturing)
• Automation
• Data collection and analysis
• Leaner processes

However, the main aim of industry 4.0 is to enable manufacturers to develop more ingenious processes that optimise production and allow the changing demands of markets to be met. The focus on digitalisation, data, connectivity and automation opens up routes to facilitate this.

What are the benefits of implementing intelligent processes into your plant?

Many benefits can be accessed by introducing the processes associated with industry 4.0 into your factory. We have listed the most prominent below.

Tailoring output to customer demand

The demands facing the industry are forever changing, with market demand becoming more complex. Customers are looking for products that precisely suit their needs in today’s world.

In food processing, as an example, this could include lines that cater to different dietary requirements, including low-calorie, vegan, vegetarian, high in protein, organic, etc.

This places added pressure on manufacturers to meet the various needs of the market and offer choice – either directly to consumers or to win contracts with other businesses.

Using data collection and smart processes, you will better understand the market’s needs and create products accordingly. It also facilitates customisation, allowing the production of output that meets specific and varying requirements.

Improved planning

Another benefit of introducing data analysis across your production is making the planning stage easier. This includes better demand forecasting or efficient stock inventory management based on precisely what you need to produce.

This is particularly valuable at a time when many businesses are still experiencing the ramifications of the supply chain crisis on their operations. With better data inputs, you are able to more accurately plan production.

Refine performance

One of the most significant advantages of intelligent processes is that they empower the optimisation of production lines. By using data to analyse performance and identify room for improvement, alongside suitable systems and functions that facilitate the accurate and effective processing of your products, you will create the best conditions.

With a strong foundation for your production and time spent refining the process, you will be able to unlock improved results with minimal room for error and reduced risk of downtime. This leads to a more productive work environment that fulfils targets consistently.

Reduce labour requirement

In most cases, the introduction of intelligent processes into your plant will reduce manual input. This is especially true of automated equipment, including robots and AI.

With skills shortages affecting the UK and leaving vacancies in many factories, the reduced labour requirement will be welcome. It also reduces the risk of user error, with innovative equipment able to process products independently. Lessening the need for manual intervention also frees up staff to do other tasks, improving productivity and speeding up timeframes.

Lower costs

By optimising conditions across your plant via industry 4.0 principles, you will minimise costs. Many factors will have an impact, including:

• The reduction of waste and product giveaway through refined processes, allowing you to produce more from your resources
• Minimising energy consumption with quicker turnaround times and efficient equipment
• Reduced labour costs through automated processes
• Preventing the risk of substandard products which could lead to the re-processing of lines
• Improving quality, reducing the risk of product recalls or refund demands

Lowering costs improves profitability across your plant and keep all stakeholders satisfied while also offsetting the risk of inflation and fluctuating prices currently impacting the industry.

Drive quality

Through an improved production environment that maximises performance, you build the criteria for high-quality output.

By driving quality, you tick many boxes. This includes improved protection for your consumers, without contamination and other issues causing potential hazards, compliance to industry standards and increased customer satisfaction.

It also enables you to develop a reputation as a trusted supplier in the industry, which will bring favourable attention to your business and help you win more contracts. This, in turn, improves sales and empowers long-term growth and profit.

Increase sales

Alongside quality improvements that fuel sales, more effective processes in your plant will improve your turnaround times and generate larger output volumes, allowing you to meet greater levels of demand.

Better yet, this should be done in a cost-effective way that minimises cost – assuming you are effectively embodying the principles of industry 4.0 – leading to improved profitability.

This is alongside the ability to increase customisation across your production, enabling you to cater to new product types and allowing you to pick up a more comprehensive range of projects. 

Meet net-zero goals

Another part of the industry 4.0 principles is a focus on lean manufacturing. This is manufacturing which utilises processes to reduce waste and maximise productivity.

With an increasing push for better sustainability across businesses and pressure to meet the government’s net-zero targets, introducing lean production into your plant enables you to meet green objectives. This includes minimising waste (through product giveaway or output that does not meet specifications), reducing energy consumption (through faster turnaround times and highly efficient equipment), utilising natural resources where possible and extending the lifecycle of your machinery (through regular maintenance, which prevents the need to replace as often).

As well as enabling you to do your part to support the environment, this lowers your costs and benefit your reputation as an eco-friendly business.

How to introduce industry 4.0. into your plant

Industry 4.0 focuses on modernising plants and enabling them to unlock the benefits. With talk of robots and augmented reality, it is tempting to see it as a far-off reality, requiring a great deal of investment and evolution.

However, it is simpler than you think to introduce innovative processes into your plan. Below, we have listed five easy ways to implement industry 4.0.

1. Collect data from your production

If the point of industry 4.0 is to create optimal manufacturing processes, one of the most essential things you need to do for your production is introduce data collection.

Using data gives performance insight that tells you where there is room for improvement. It also flags up issues in real-time so you can react accordingly and help you improve efficiency across your machinery for leaner production.

With this knowledge, you will make meaningful adjustments to your lines to increase quality, meet customer needs and drive results.

Fortunately, data monitoring solutions simplify the process and integrate with your equipment. This includes Yamato Stats, which empowers manufacturers to access real-time analysis across lines through visualisation and easy-to-use functionality.

It also raises issues promptly, so you minimise risk and disruption in your plant and ensure a high-quality end product.

2. Invest in modern equipment

Many manufacturing solutions are now sold with the functionality listed under industry 4.0 – including data analysis, automation, connectivity, etc. Therefore, by investing in the latest equipment, you will bring this into your plant to improve results.

This doesn’t mean replacing all your equipment at once. Research the best solutions when your previous machinery comes to the end of its lifecycle, and ensure any new machinery you install comes with the necessary functionality to drive performance.

This enables you to modernise your production lines over time and quickly bring in the benefits of industry 4.0.

3. Welcome automation

Automation is a controversial topic. However, while automation will not remove the need for staff, it may reduce the number of staff required.

Introducing automation at the appropriate points of your production line will speed up turnaround times and reduce the need for manual intervention. This allows processes to run smoothly, with minimal error and always in keeping with the pre-agreed specifications.

Introducing automation should not compromise quality, so long as you find equipment with delicate handling and that is compatible with the materials you are processing.

4. Be prepared to adapt

Many manufacturers have been operating for a long time, using processes that have been proven to work over years or even decades. As such, the thought of welcoming the new era of industry can seem to be a step change too far.  However, the main focus of industry 4.0 is to access the most recent innovations in manufacturing and use them to allow for exceptional performance.

It’s vital to remember that these steps can be small scale to start with which proof the benefits of industry 4.0. The best way to do so is with an understanding of the implications for your plant, with the right infrastructure for change and training to bring your staff on board.

By staying on top of emerging technology and trends and being open to change, you will make the appropriate adjustments to your production lines, enabling you to keep up with evolving industry and your competitors.

5. Emphasise quality

One of the aims of intelligent manufacturing is to improve quality. Regardless of which tactics you implement – whether it’s robots or data analysis – your ultimate focus needs to be ensuring your output meets standards and exceeds customer expectations.

The best way to ensure quality is to think about your product requirements and customer needs. From here, you can design processes that allow you to deliver, creating high-quality products that are safe for consumption. If issues compromise quality (which data analysis will highlight), it is essential to address these quickly.

By guaranteeing quality, you maintain your reputation whilst growing your market share. You meet one of the most crucial elements of industry 4.0: meeting the changing demands of customers adequately.

Conclusion

While talk of robots and AI may seem futuristic, industry 4.0 is happening now. More and more manufacturers are implementing intelligent processes into their plants, intending to drive results and refine production.

By welcoming this new era into your plant, you ensure you are operating at your maximum performance and gaining an edge over the competition. The knock-on benefits include reduced costs, improved sustainability, better quality output and increased productivity – making it a win-win for your plant.

Better yet, it is easier than you may think to introduce industry 4.0 into your plant.

Yamato helps you adapt to the changing landscape of manufacturing with our smart solutions, including Yamato Stats, automated machinery, and interconnective equipment with embedded data analysis.

Get in touch with us today to discuss the needs of your production and how we can help you optimise your processes.