Industry 4.0: The Future of Indo-German Industrial Collaboration

Industry 4.0 can be described as the fourth industrial revolution, a mega- trend that affects every company around the world. It envisions interconnections and collaboration between people, products and machines within and across enterprises. Why does Industry 4.0 make for an excellent platform for industrial collaboration between India and Germany? The answers lie in economic as well as social factors. Both countries have strengths and weakness and strategic collaboration using the principles of Industry 4.0 can help both increase their industrial output, GDP and make optimal use of human resources. As a global heavy weight in manufacturing and machine export, Germany has a leading position in the development and deployment of Industry 4.0 concepts and technology. However, its IT sector, formed by a labor force of 800,000 employees, is not enough. It needs more professionals to reach its full potential. India, on the other hand, is a global leader in IT and business process outsourcing. But its manufacturing industry needs to grow significantly and compete globally. These realities clearly show the need for Industry 4.0-based collaboration between Germany and India. So how does Industry 4.0 work? In a first step, we look at the technical pers- pective – the vertical and horizontal integration of Industry 4.0 principles in enterprises. Vertical integration refers to operations within Smart Factories and horizontal integration to Smart Supply Chains across businesses. In the second step, we look at manufacturing, chemical industry and the IT sector as potential targets for collaboration between the two countries. We use case studies to illustrate the benefits of the deployment of Industry 4.0. Potential collaboration patterns are discussed along different forms of value chains and along companies’ ability to achieve Industry 4.0 status. We analyse the social impact of Industry 4.0 on India and Germany and find that it works very well in the coming years. Germany with its dwindling labor force might be compensated through the automation. This will ensure continued high productivity levels and rise in GDP. India, on the other hand has a burgeoning labor market, with 10 million workers annually entering the job market. Given that the manufacturing sector will be at par with Europe in efficiency and costs by 2023, pressure on India’s labor force will increase even more. Even its robust IT sector will suffer fewer hires because of increased automation. Rapid development of technologies – for the Internet of Things (IoT) or for connectivity like Low-Power WAN – makes skilling and reskilling of the labor force critical for augmenting smart manufacturing. India and Germany have been collaborating at three levels relevant to Industry 4.0 – industry, government and academics. How can these be taken forward? The two countries have a long history of trade. The Indo-German Chamber of Commerce (IGCC) is the largest such chamber in India and the largest German chamber worldwide. VDMA (Verband Deutscher Maschinen- und Anlagenbau, Mechanical Engineering Industry Association), the largest industry association in Europe, maintains offices in India. Indian key players in IT, in turn, have subsidia- ries in Germany and cooperate with German companies in the area of Industry 4.0. Collaboration is also supported on governmental level. As government initiatives go, India has launched the “Make in India” initiative and the “Make in India Mittelstand! (MIIM)” programme as a part of it. The Indian Government is also supporting “smart manufacturing” initiatives in a major way. Centers of Excellence driven by the industry and academic bodies are being set up. Germany and India have a long tradition of research collaboration as well. Germany is the second scientific collaborator of India and Indian students form the third largest group of foreign students in Germany. German institutions like the German Academic Exchange Service (DAAD) or the German House for Research and Innovation (DWIH) are working to strengthen ties between the scientific communities of the two countries, and between their academia and industry. What prevents Industry 4.0 from becoming a more widely used technology? Recent surveys in Germany and India show that awareness about Industry 4.0 is still low, especially among small and medium manufacturing enterprises. IT companies, on the other hand, are better prepared. There is a broad demand for support, regarding customtailored solutions, information on case studies and the willingness to participate in Industry 4.0 pilot projects and to engage in its platform and networking activities. We also found similar responses at workshops conducted with Industry 4.0 stakehold- ers in June 2017 in Bangalore and Pune and in an online survey. What can be done to change this? Both countries should strengthen their efforts to create awareness for Industry 4.0, especially among small and medium enterprises. Germany should also put more emphasis on making their Industry 4.0 technology known to the Indian market. India’s IT giants, on the other hand, should make their Industry 4.0 offers more visible to the German market. The governments should support the establishing of joint Industry 4.0 collaboration platforms, centers of excellence and incubators to ease the dissemination of knowledge and technology. On academic level, joint research programs and exchange programs should be set up to foster the skilling of labor force in the deployment of Industry 4.0 methods and technologies

Benchmarking of Tools for User Experience Analysis in Industry 4.0

Abstract Industry 4.0 paradigm is based on systems communication and cooperation with each other and with humans in real time to improve process performances in terms of productivity, security, energy efficiency, and cost. Although industrial processes are more and more automated, human performance is still the main responsible for product quality and factory productivity. In this context, understanding how workers interact with production systems and how they experience the factory environment is fundamental to properly model the human interaction and optimize the processes. This research investigates the available technologies to monitor the user experience (UX) and defines a set of tools to be applied in the Industry 4.0 scenario to assure the workers' wellbeing, safety and satisfaction and improve the overall factory performance

An Overview of the Rising Challenges in Implementing Industry 4.0

Industry 4.0 is the fourth industrial revolution that was first introduced in Germany which then becomes a trend of future manufacturing industries. The Industry 4.0 also referred as the umbrella concept for new industrial paradigm which consists of a number of future industry characteristics, were related to cyber-physical systems (CPS), internet of things (IoT), internet of services (IoS), robotics, big data, cloud manufacturing and augmented reality. By adopting these technologies as the key development in more intelligent manufacturing processes including devices, machines, modules, and products, the process of information exchange, action and control will stimulate each other, subsequently to an intelligent manufacturing environment. However, in order to fully utilize the advantages of industry 4.0, there are some challenges that need to be overcome. This paper reviews the challenges in implementing Industry 4.0. The literatures found in this paper mainly from Google Scholar, Science Direct and Emerald. In short, the challenges can be imparted into seven major categories. There are data management and Integration, knowledge-driven, process, security, capital, workforce, and education

Ethical issues invoked by Industry 4.0

Industry 4.0 is universally referred to as the fourth industrial revolution. It is a current trend of automation and data exchange in manufacturing technologies. The computerisation of manufacturing includes, amongst other, cyber-physical systems, the Internet of Things (IoT), cloud computing and cognitive computing. There are many challenges in the realisation of Industry 4.0. In order to adopt a "smart factory" and improved (software) processes many ethical considerations need to be identified and considered if a company is to obtain an ethical development and deployment of Industry 4.0. The purpose of normative ethics is to scrutinise standards about the rightness and wrongness of actions, the ultimate goal being the identification of the true human good. A rational appeal can be made to normative defensible ethical rules in order to arrive at a judicious, ethically justifiable judgement. In this position and constructive design research paper our steps are: First we report on the findings of a broad literature review of related research, which refers to the current challenges in the realisation of Industry 4.0. Second, we identify and list some basic generic Deontological and Teleological ethical principles and theories that can serve as normative guidelines for addressing the challenges identified in the initial step. Third, we prescribe a set of ethical rights and duties that must be exercised and fulfilled by protagonists/stakeholders in Industry 4.0 implementation in order for them to exhibit ethical behaviour. Each of these suggested actions are substantiated via an appeal to one, or a number of the normative guidelines, identified in the second step. By identifying and recommending a set of defensible ethical obligations that must be fulfilled in the development and deployment of smart factories, protagonists such as: employers, project managers, technology suppliers, trade unions, (on a microscopic level) and chambers of commerce, local and national government (on a macroscopic level) and other can fulfil their ethical duties. Thus, a deployed Industry 4.0 solution can result in technological change, social change and changes in the business paradigm, which are all ethically justifiable. Ultimately all the improvement processes of Industry 4.0 implementation must be underpinned with ethical consideration

Industrial automation based on cyber-physical systems technologies: Prototype implementations and challenges

Cyber-Physical Systems (CPS) is an emergent approach that focuses on the integration of computational applications with physical devices, being designed as a network of interacting cyber and physical elements. CPS control and monitor real-world physical infrastructures and thus is starting having a high impact in industrial automation. As such design, implementation and operation of CPS and management of the resulting automation infrastructure is of key importance for the industry. In this work, an overview of key aspects of industrial CPS, their technologies and emerging directions, as well as challenges for their implementation is presented. Based on the hands-on experiences gathered from four European innovation projects over the last decade (i.e. SOCRADES, IMC-AESOP, GRACE and ARUM), a key challenges have been identified and a prioritization and timeline are pointed out with the aim to increase Technology Readiness Levels and lead to their usage in industrial automation environments.The authors would like to thank for their support the European Commission, and the partners of the EU FP6 SOCRADES (www.socrades.net), EU FP7 GRACE (www.grace-project.org), EU FP7 IMC-AESOP (www.imc-aesop.eu) and EU FP7 ARUM (www.arum-project.eu) projects, for their fruitful support and discussions.info:eu-repo/semantics/publishedVersio

Energy efficiency in discrete-manufacturing systems: insights, trends, and control strategies

Since the depletion of fossil energy sources, rising energy prices, and governmental regulation restrictions, the current manufacturing industry is shifting towards more efficient and sustainable systems. This transformation has promoted the identification of energy saving opportunities and the development of new technologies and strategies oriented to improve the energy efficiency of such systems. This paper outlines and discusses most of the research reported during the last decade regarding energy efficiency in manufacturing systems, the current technologies and strategies to improve that efficiency, identifying and remarking those related to the design of management/control strategies. Based on this fact, this paper aims to provide a review of strategies for reducing energy consumption and optimizing the use of resources within a plant into the context of discrete manufacturing. The review performed concerning the current context of manufacturing systems, control systems implemented, and their transformation towards Industry 4.0 might be useful in both the academic and industrial dimension to identify trends and critical points and suggest further research lines.Peer ReviewedPreprin

IAMM: A maturity model for measuring industrial analytics capabilities in large-scale manufacturing facilities

Industrial big data analytics is an emerging multidisciplinary field, which incorporates aspects of engineering, statistics and computing, to produce data-driven insights that can enhance operational efficiencies, and produce knowledgebased competitive advantages. Developing industrial big data analytics capabilities is an ongoing process, whereby facilities continuously refine collaborations, workflows and processes to improve operational insights. Such activities should be guided by formal measurement methods, to strategically identify areas for improvement, demonstrate the impact of analytics initiatives, as well as deriving benchmarks across facilities and departments. This research presents a formal multi-dimensional maturity model for approximating industrial analytics capabilities, and demonstrates the model’s ability to assess the impact of an initiative undertaken in a real-world facility

digitalization technologies for industrial sustainability

Abstract Digital technologies are shown to perform a potential role in developing a resource efficient industrial base. The effective adoption of them can help to deliver reduced costs and improve the flexibility and sustainability of manufacturing systems. However, these positive benefits are far from guaranteed and the way in which digital technologies favor the transition towards sustainable manufacturing systems has not been analyzed in detail yet, so more conceptual and empirical investigations are required in this field. This paper develops a conceptual framework, which explains the potential significance of using digital technologies toward efficiency, resilience and sustainability. It also includes evidence from various case studies, which illustrate the core technologies which can potentiality contribute to a sustainable industrial future. The findings show some impressive results concerning the sustainable implications of the digitalization of manufacturing processes. If the predicted benefits can be achieved through digital technologies, they could massively impact on sustainability