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Integrated Industry MANUFACTURING OF THE FUTUREJAYESH C S PAI

Manufacturings next actAstonishing rise in data volumes, computational power, and connectivity, especially new low-power wide-area networksEmergence of analytics and business-intelligence capabilitiesNew forms of human-machine interaction such as touch interfaces and augmented-reality systemsImprovements in transferring digital instructions to the physical world, such as advanced robotics and 3-D printing.

INDUSTRIE 4.0Connected IndustryManufacturing facilities that share information with work pieces and call a technician for help if neededContinuous data exchange between all participating units from the production robot to inventory management to the microchip. This connects all production and logistics processes together, making the industry more intelligent, efficient and sustainable.

Digitalizing plants - Digital Factory Integrated engineering from planning to operation. Digital Factory is a virtual image of the real production that shows the production processes in a virtual environment.Process plants today are highly complex and have lifecycles of many years. For this reason it is even more important to replace cost-intensive physical tests and prototypes by simulation from virtual commissioning, simulation parallel to operation, through to error identification and plant optimization. The repeated, and thus error-prone entry of data already captured in a different context, must be replaced by a consistent digital process chain. Documents no longer need to be available in printed form. Instead, updated plant descriptions and plant layouts should always be available online. The benefit is clear: speedier and safer planning, parallel engineering, faster commissioning, safer operation and updated documentation.

WHAT CAN WE EXPECT IN A COMPANY IMPLEMENTING DIGITAL PRODUCTION?

The implementation of the digital business achieves significant benefits:1 Cost savings through better use of resources of 30%,2 The cost savings achieved by optimizing material flows 35%,3 Reduction of the number of machines, tools and workplaces by 40%,4 Total manufacturing production growth of 15%,5 Reduce time to market for new products by 30%.

The Web of TechnologiesThe full digitization of a companys operations, integrated vertically (to include every function and the entire hierarchy) and horizontally (linking the suppliers, partners, and distributors in the value chain and transferring data among them seamlessly).The redesign of products and servicesto be embedded with custom-designed software, so that they become responsive and interactive, tracking their own activity and its results, along with the activity of other products around them.Closer interaction with customers, enabled by these new processes, products, and services.

Integrated EnergyEnergy systems are digitally controlled and machines exchange information with products - the era of networked industry.Good use of energy not only means utilizing it more efficiently, but also sensibly combining renewable energy production and the right energy storage in an integrated energy system.Hybrid smart grids such as photovoltaic systems on rooftops, biogas plants, business-owned CHP plants etc. ensure the efficient coordination of production, storage, grid management and consumption so that suppliers maintain a smooth system. New measurement, control and regulation technologies need to be integrated into the conventional grid to make this possible.

SMART MATERIALS & COATINGSThe Future is light and easyReducing energy and material consumption has become necessary to stay competitive in nearly every sector of industry. Materials having sensoring properties that turn them into smart materialsNanotechnology coatings make smart materials out of everyday things.New adhesives think for themselves3D printing revolutionizes manufacturingSurface coatings can fundamentally change the properties of materials; they reduce wear, repel water and impurities and even act as filters.

SMART ADHESIVESFire-resistant sealantsDiaper adhesives that change color when wet and send signals

3D Printing Disrupting Global Mfg1. True Rapid Prototyping. Automation is making products that would need a month to go through three or four design changes in the prototyping phase now taking a week. Products are getting to market faster, and companies are saving significant time and money.2. Rapid Design Iteration (A/B testing of physical products). Ford is 3D-printing molds in four days at a cost of $4,000 instead of six months and costing hundreds of thousands of dollars.3. Low volume production. With conventional manufacturing, a company has to commit to creating tooling or molds before a single end use part can be produced. With 3D printing, there are no set-up costs whatsoever.4. Mass Customization. Large quantities of an item are produced, each one customized like your actual knee is scanned and a perfect replica is printed and ready for you prior to surgery.5. Virtual Inventory. Inventories around the world will soon shrink dramatically as holding inventory is very expensive.We make what we need, when and where we need it.6. The Long Tail of Parts. Older but still-useful products dont become waste; their lifespan need not be pre-determined by scale production limitations. We can print any part for as long as it is needed.7. Product Innovation Renaissance. Lower entry barriers and ability to enable radically more complex and useful objects are initiating a new era of product innovation.

GE is using 3D metal printers to produce fully redesigned new fuel injection system for jet engines, reducing components from 21 parts to 1 and incorporating geometries that are simply impossible to create using any other manufacturing method, resulting in astonishing increases in efficiency.

Lightweight design gives greater flexibility in manufacturing

From vehicles to rotor blades, from construction to home furnishingsthe trend to lightweighting, necessitated by the need for energy efficiency and environmental protection, is now everywhere in our lives.

In the automotive sector, plastics are evolving from non-load-bearing decorative components to high-strength functional and structural components that require excellent resistance to impact and heat.

Large-scale Lightweight Construction InitiativeSteel offers significant scope for reducing raw material and energy consumption, which is nowhere near fully utilized yet.Possibilities for reducing weight and raw material consumption for forged components have been exploredSavings could be found primarily in the drive train and chassis: wheel hubs and injection system, crankshaft, gears and other components. Redesign and development is not that simple in the metal production and processing sector, with its high division of labor.Casting simulation allows to reliably predict the performance of a given component under operating conditions

Functionally Optimized ConstructionManufacturers are currently required to integrate the increasing number of drive concepts and energy storage systems into vehicle structures. The vehicle bodies of tomorrow, particularly in view of alternative drive systems in small series with lots of different versions, will not only need to be lighter, but above all will also require a highly flexible design. The consequence is an increasing number of vehicle derivatives, which demand adaptable bodywork concepts that are economical to manufacture.

EDAG concept car Light Cocoon

Surface coatings that change components' aerodynamic properties

Predictive Maintenance

MINIMIZING DOWNTIMETechnology manufacturers are equipping machines and industrial systems with sensors that enable remote monitoring when combined with the right software.Defective components that could soon lead to a system shutdown are identified independently of the usual maintenance schedule, and can be replaced before damage actually occurs.Continuous data analysis gives users of smart machines a much more precise picture of their facilities: Operating errors or wrong settings become a thing of the past in this scenarioPredictive maintenance thus moves into predictive producing and a production unit becomes a veritable smart factory.

Predictive maintenanceIndustry 4.0 is about interconnectedness the digital integration of machines, products, components and up- and downstream systems. With predictive maintenance, sensors tap into this interconnectedness to continuously capture in-service machinery condition data, combine it with data from other systems, such as ERP and CRM software, and analyze it. In this way, predictive maintenance detects the early warning signs of outages and triggers the necessary preventive measures.Predictive maintenance offers three main benefits: improved production planning, greater machine availability and a reduction in unscheduled plant shutdowns.

Cobot (Collaborative Robot)Designed to work alongside human workers, assisting them with a variety oftasks. Co-bots are affordable, highly adaptable, and almost plug-and-playAs OEMs come under increasing pressure to increase automation in order to satisfy extremely high-quality expectations at the right price, collaboration between robots and humans working side by side on the production line can eliminate unwanted variabilities without losing the human touch needed to complete complex assembly tasks, individualize products where needed, or deal with exceptional events.Collaborative robots can also assist operators in space-constrained workplaces such as laboratories, which can benefit from automating tasks such as dispensing or loading/unloading but are unable to accommodate the guarding needed for a conventional robot.

HOW COBOTS ARE DIFFERENT FROM ROBOTS.1. Partnering in human-machine teams2. Relief from risky activities3. "Smart" and safe behavior4. Flexible and teachable5. Usable anywhere

Integrated EnergyEnergy resources can be efficiently piloted using management systems. Todays energy planners must strive to balance many conflicting factors. At the most basic level, they must seek to balance energy needs (demand) and energy resources (supply) across two dimensions: Ensuring access to adequate, affordable and secure energy services to satisfy human needs and achieve socioeconomic development. Promoting production and use of energy services in ways that are consistent with the pursuit of sustainability.Systematic analysis of all the factors that influence the evolution of energy systems. It facilitates problem solving and makes it possible to explore linkages, evaluate trade-offs and compare consequences, thereby helping countries to develop an effective energy strategy that supports national sustainable development goals.

ENERGY CONCEPTS OF THE FUTUREReducing energy consumption is more than a matter of image. From energy recovery to autonomous power stations, modern technologies are achieving efficiency ratings, that also have a remarkable effect on the bottom line.Efficiency is the ratio of cost to result. This common economic principle certainly applies to energy savings: If you can achieve the same or even a better result at lower cost, your efficiency increases.

Learning energy efficiency networksTen or fifteen companies from the same sector or the same region meet regularly to share knowledge around energy savings, and take advantage of synergies. Instead of each one having to research for itself how to use their energy more efficiently, their shared knowledge grows exponentially for all.

Energy efficiencyEnergy efficiency: Intelligently manage electricity and climate control!Use energy efficiently, identify and take advantage of potential savings, reduce in-house costs Integrated Energy makes all this possible. Energy Productivity - An energy-flexible factory is built on three pillars: building technology including energy storage, production planning and production control systems, and the machinery proper.Reduce its total emissions by 40 percent

"Digital Energy"Legal obligations relating to energy audits, rising costs and the prospect of tax concessions and government grants are leading to increased interest in energy management systems, especially in energy-intensive sectors such as the pulp industry, steel and food production, metalworking and earthworks. However, energy flows in manufacturing and production and the associateinfrastructure can only be optimized through effective acquisition and analysis of the relevant data. This is where "Digital Energy" comes in. Energy systems will be digitally controlled.

The Digital Power Plant Pays DividendsCustomers are reaping the benefits of going digital in greater power output, better fuel efficiency, reduced emissions and an ability to meet market demands as they change from day to day. Whether for a single power plant or across a fleet, power companies are mapping their transformation, beginning with connecting and monitoring assets and moving to leveraging insights for dispatch optimization.No matter the fuel: fossil, coal-fired steam or nuclear, digital is transforming the way power plants are managed toward improved productivity, safer and more secured operations and greater profitability.

Energized FutureReduceCut down on energy costs and consumption by switching to energy-saving technology like LEDs.ProduceBecome more energy independent by adopting on-site generation like solar and combined heat and power.ShiftUse energy storage, electric vehicle charging and demand response to reduce energy costs and carbon footprints.OptimizeHarness data insights from the Industrial Internet to improve performance, create efficiencies and plan for the future.

How to make it happenSolar SolutionsGain energy independence by generating lower-cost, renewable solar energy on site.LED LightingLEDs are an environmentally friendly lighting solution that deliver huge long-term energy savingsand can be integrated with an array of intelligent hardware.Energy StorageOn-site energy storage offers reduction in demand charges and helps protect factories and warehouses from grid vulnerabilities.Intelligent EndpointsSensors, motion detectors, Wi-Fi-enabled monitoring, energy load controls and more can be installed into LED fixtures or other hardware to collect valuable data about your operation.

Energy Efficiency CentreMain objectives of EEC are:Support to renewable energy and energy efficiency utilization for sustainable development and as a result improve national energy security level and minimize negative environmental impact.Increase awareness of the civil society and the countrys decision makers on the environmentally friendly and economically sound ways of energy production and consumption as well as on the potential for renewable energy and energy efficiency.

DECENTRALISED ENERGYDecentralised energy, as the name suggests, is produced close to where it will be used, rather than at a large plant elsewhere and sent through the national grid.This local generation reduces transmission losses and lowers carbon emissions. Security of supply is increased nationally as customers dont have to share a supply or rely on relatively few, large and remote power stations.There can be economic benefits too. Long term decentralised energy can offer more competitive prices than traditional energy. While initial installation costs may be higher, a special decentralised energy tariff creates more stable pricing.

TrigenerationProduction of electricity, heat and cooling in one process

Motion, Drive & AutomationOne consequence of Industry 4.0 is that power transmission and fluid power products (Antifriction bearings, gearboxes, pumps, cylinders and valves, linear motion systems) are now sources of big dataManufacturers of power transmission and fluid power technologies integrate mechatronic and CPS (cyber-physical systems) modules which are key enablers of efficient, intelligent Industry 4.0 production processes. By incorporating digital connectivity, these modules facilitate integration across the control and production layers, thereby helping to pave the way for a new era in manufacturing characterized by intelligent, self-optimizing and autonomous processes.Predictive maintenance detects the early warning signs of outages and triggers the necessary preventive measures.

Cloud-based manufacturingCapturing and applying company-wide intelligence and knowledge through the use of analytics, business intelligence (BI), and rules engines.Piloting and then moving quickly to full launch of supplier portals and collaboration platforms, complete with quality management dashboards and workflows.Designing in services is now becoming commonplace, making cloud integration expertise critical for manufacturers.Accelerating new product development and introduction (NPDI) strategies to attain time-to-market objectives.Managingindirect and direct channel sales from a single cloud platform tracking sales results against quota at the individual, group and divisional level is now commonplace across all manufacturers visited.Using cloud-based marketing automation applications to plan, execute and most important, track results of every campaign.Automating customer service, support and common order status inquiries online, integrating these systems to distributed order management, pricing, and content management platforms.Increasing reliance on two-tier ERP strategies to gain greater efficiencies in material planning, supplier management and reduce logistics costs.Reliance on cloud-based Human ResourceManagement(HRM) systems to unify all manufacturing locations globally.

Research and innovationTodays ideas are tomorrows innovations. Exchanging knowledge for the products of tomorrow.Because it brings together supply and demand in the market of ideas.Scarce resources must be used ever more efficiently. Product cycles are becoming shorter. Customers want increasingly individualised products. As a result, industrial production is becoming more dynamic. The flexibility and complexity of production systems is increasing. This is linked to a fundamental need for research and developmentAdaptronics, Bionics, Organic Electronics, Textile Solutions, Energy and Mobility Research, Nano and Microtechnology

Bio-economyBioeconomy comprises those parts of the economy that use renewable biological resources from land and sea such as crops, forests, fish, animals and micro-organisms to produce food, materials and energy. The overarching goal is to reduce dependence on petroleum and other fossil fuels.

Organic ElectronicsThere are good economic and ecological arguments in favour of using organic materials in light fittings, photovoltaic collectors, printed circuit boards and batteries

BionicsNature is an unparalleled designer and innovator. Industrial companies have begun exploring new bionic avenues in search of innovative lightweight design concepts, as well as functional, adaptive and resource efficient materials.

AdaptronicsThe adaptive structure technology is based on functional integration by combining conventional structures with active material systems, which extend classical load-bearing and form-defining structure performance by including sensor and actuator functioning. In connection with suitable adaptive controller systems, adaptive structure systems can adapt to their respective operational environment optimally.The adaptive structure technology pursues two main goals:1. Adaptronic allows the continuous intervention in structural-mechanical and structural-dynamic characteristics of the complete system.2. The adaptive structure technology is aimed at the optimization of the structural system by replacing structure components with adaptronic, multi-functional (effective in the sensor-actor sense) components to save mass and designed space.

NOISE CANCELLATION

Textile SolutionsIndustry has been quick to recognize the potential benefits of textile solutions i.e. flexibility, low weight, air permeability, weather resistance and high mechanical durability.Tick-repellent textiles, air conditioning for barns, and embroidered electronicsTextile 4.0 would be a process chain of independent production. Information carrier can be textile material container, bobbin, warp beam, and fabric. Radio frequency identification technology (RFID) and sensors are basic to collect and store information, such as equipment operation status, and maintenance information. The plant will self-configure and self-optimize quickly and flexibly to meet custom manufacturing orders.

Nanotechnology, Virtual Reality.

Micro-Nano AreaMicrostructures and sensor systems, Intelligent laser processing systems, High-precision 3D measuring techniques, Energy harvesting applications

Intelligent manufacturing you can touchSmart Factory: Integrated manufacturing leads to customized products! In the future, everything will be integrated now it depends on the network!Enterprise Resource PlanningManufacturing Execution System, MESIndustry 4.0 is revolutionizing manufacturing by gradually moving from closed systems to partially-open systems and then, ultimately, to completely open systems.More than within the company, intelligence-based and information-based operations also should include suppliers and contractors qualified to participate in supply chains

DIGITAL TWIN TECHNOLOGY THAT IS CHANGING INDUSTRYhttps://www.slideshare.net/jayeshcspai/digital-twins-technology-that-is-changing-industry

World of Work 4.0Opportunity or risk?47 percent of workers could lose their job as a result of automation and digitisation during the next 20 years.Many new jobs will result from digitisation.Lifelong learning will need to be more naturally and more systematically rooted in our education system.Flexibility is the Slogan

Supply 4.0: Faster. More flexible. More innovative

The key to optimizing operational processes in an Industrie 4.0 strategy is a fully digitalized supply chain that allows the entire flow of goods and processes to be controlled online, making it transparent to participants. The increase in transparency results in a reduction of transport damages and an improvement in quality.Characteristic of this are automated transactions and embedded intelligence, optimized and connected data flows, and strategies based on real-time data and simulations.Four key technologies: Supply chain visibility platforms/solutions, Big Data/analytics, Cloud computing, and Simulation tools.

PLMIn the discrete manufacturing industry it means Product Lifecycle Management, whereas in the process industry it means Plant Lifecycle Management. The backbone of this is digitalization : a central source for all data regarding a product, from the initial idea and production to sales and marketing.Action areas: PLM01: Digital models02: Smart products03: Smart factories04: Smart service

MadeinChina_2025https://www.slideshare.net/jayeshcspai/china-2025