Industry 4.0: the keys to successful transformation18 November 2021
Beyond the health crisis we have experienced, the industry is facing a double transformation. The digital and environmental shift is at the heart of all discussions and the sector is experiencing a revolution: Industry 4.0.
This theme was addressed by “Global Industrie“, which kicked off the industrial season last month by bringing together the entire ecosystem with 45,000 visitors. What a pleasure to meet again at a face-to-face exhibition!
A real political highlight, the 2021 edition was an opportunity for the National Industry Council to welcome the Prime Minister Jean Castex, the Minister for the Economy, Finance and Recovery Bruno Le Maire and the Minister Delegate in charge of Industry Agnès Pannier-Runacher, to take stock of the industry in France.
Increased competitiveness, equipment modernisation, reduced environmental impact… The benefits of Industry 4.0 are numerous. But what are the keys to a successful strategy? To answer this question, let’s take a look at the testimonies of DELFINGEN, JPB SYSTEM, RENAULT, ST MICROELECTRONICS, FPT POWERTRAIN TECHNOLOGIES and ENNOVIA, speakers at the Global Industrie 2021 conferences.
THE CHALLENGES OF THE INDUSTRY
A complex industrial environment requires certain factors to be taken into account. While many companies have launched isolated pilot projects, few have succeeded in deploying an Industry 4.0 strategy on a large scale throughout their activities. The causes?
A heterogeneous machine park
During its presentation, ENNOVIA explained that the installations of large factories have up to 20,000 machines. So many different protocols and languages need to be aligned to ensure interoperability between these machines of different generations and technologies. The maintenance sector, for example, poses the problem of harmonising data to obtain up-to-date information on the state of equipment.
The issue of cyber security
The rapprochement between the industrial world (OT) and the digital world (IT) is inevitable. However, the integration of connected equipment in factories gives rise to new forms of IT threats. The need to implement IT security strategies and measures becomes a crucial issue for ensuring security in transmission.
Fragmentation of market players
The implementation of a smart manufacturing project is confronted with a multitude of different players in the market: sensor manufacturer, connection expert, analysis expert to process data and derive business value… Few suppliers offer a complete service with a real knowledge of the industrial world.
A tense labour market
In a context of talent shortage, the industrial market, particularly the maintenance market, is struggling to recruit qualified profiles. The reasons for this are rare training courses, a profession that has long been neglected, and a high-pressure job… The industrial professions are currently short of candidates.
THE LEVERS OF A SUCCESSFUL INDUSTRY 4.0 STRATEGY
Customised, turnkey solutions for the field
Even the most sophisticated technology will only create value if it generates a response on the ground. To achieve this, close collaboration between the digital professions and technicians is necessary, involving managers to report any obstacles encountered.
For FPT POWERTRAIN TECHNOLOGIES, the 4.0 approach was a success thanks to positive communication from the field: the technicians themselves presented their solutions to their colleagues.
An end-user centric approach has guided the design and development of the DiagRAMS solution. Indeed, our software integrating a double expertise in AI and Industry, has been designed in collaboration with a panel of users from various industries.
Data: the absolute key of an Industry 4.0 strategy
Data is the main pillar of Industry 4.0. The number of IoT devices is growing, as is the amount of data they generate: 33 zettabytes of data worldwide in 2018 and 175 zettabytes by 2025*. Big Data is shaking up existing models in factories and some manufacturing companies have understood this and are seeking to take advantage of the value of data.
FPT gives us its feedback on the different levels of solutions expected:
- 1st level – Visualisation: summarising the data graphically
- 2nd level – Analysis: understanding the data
- 3rd level – Decision-making:
- descriptive (what happened)
- diagnosis (why it happened)
- predictive (what will happen)
- prescriptive (what I should do)*
In response to market expectations, DiagRAMS integrates these different levels into its software to help manufacturers exploit the intelligence of their data. Our predictive maintenance solution provides decision support for more effective production management and failure prediction.
A human-centred approach
Beyond technological and organisational development, a successful 4.0 approach requires new processes and mindsets to ensure widespread adoption and lasting impact. Giving meaning and recognition are the watchwords of a successful transformation. The aim is to transmit the keys to becoming autonomous without imposing anything on your employees.
A philosophy that we apply at DiagRAMS by developing a simple and intuitive solution. Our tool, based on Machine Learning technology, allows technicians to gain autonomy so that they can concentrate on tasks with higher added value and thus increase their skills.
For DELFINGEN, this change involves demystifying the industry of the future. Thus, the automotive equipment manufacturer is offering its employees an acculturation programme to introduce 3D printing to their teams and thwart preconceived ideas.
INDUSTRY 4.0, A MUST FOR TOMORROW
Industry 4.0 is a competitive advantage for today and will be essential for tomorrow. It will be implemented in most sectors within the next 5 years** to enable manufacturers to prosper and apply a policy of continuous improvement. That’s why it’s important to start testing dedicated solutions now.
Industry players are showing us the way at Global Industrie 2021 by sharing their feedback and best practices for achieving operational excellence. They demonstrate that successful digital transformation requires a clear understanding of the market, the organisation’s asset base (machines, HR, technologies) and its objectives.
To help you take advantage of these developments, DiagRAMS offers global monitoring software that enables you to anticipate breakdowns and malfunctions thanks to Artificial Intelligence algorithms dedicated to industrial data. The benefits: improving your ROI, attracting young profiles in search of digital tools, facilitating interventions in the field, improving the quality of your products and reducing your environmental impact.
*Study conducted by CCI France
**Siemens study – Industry 4.0: Rising to the challenge