In terms of global meaning, the Industry 4.0 concept is widely accepted as representing the digitalization of manufacturing. The ‘4.0’ provides a historical context, positioning this new phase as the fourth transformation in production. The first industrial revolution was depicted by mechanization through water and steam power; the second saw the concept of mass production through electric power; and the third resulted in the rise of the computer and automation. Now we have the fourth breakup in manufacturing – the creation of truly smart factories with cyber-physical systems and communication across the Internet of Things.
According to global management consultancy McKinsey, Industry 4.0 is driven by four identifiable technology trends:
Germany is widely credited as being the founding nation of the Industry 4.0 concept, with the name emerging from a national strategic initiative to establish the country as a lead provider of advanced manufacturing systems. The country has one of the most competitive manufacturing industries in the world, and it is supported by a network of state-of-the-art research and development facilities.
Germany’s strong machinery and plant manufacturing industry, its globally significant level of IT competences and its know-how in embedded systems and automation engineering mean that it is extremely well placed to strengthen its position as one of the world’s leading developers of Industry 4.0 technologies.
If Germany has set the pace in terms of adoption of Industry 4.0 and the emergence of smart factories, it is sure to face a stiff challenge to its position of leadership from the US, which over the next five years is expected to invest more capital into the digitalization of manufacturing than any other nation or region. In the US, the Industry 4.0 better known as Industrial Internet of Things (IIoT). With this rapid advancement of technologies in the manufacturing environment, many US organizations are busy preparing themselves for the massive change that lies ahead.
According to Harvard Business Review’s From Data to Action report, the most difficult aspect for organizations to change on the route to smarter factories is their internal culture. For Industry 4.0 to reach its full potential, businesses need to establish one undisputed source of performance data, and give all decision makers the ability to receive data in real time. The philosophy of making fact-based decisions using quantitative manufacturing data will need to be coached into all levels of management.
While China remains the largest manufacturer in the world, when it comes to the adoption of Industry 4.0, the Asian powerhouse is playing catch-up with many of its economic rivals in Europe and North America. That’s largely due to historical factors: while Germany, for instance, has traditionally focused on advanced production systems, China’s strengths have always been at the lower-value end of the global manufacturing sector, where price is key. This has led to some stark imbalances: at present, there are only approximately 14 industrial robots per 10,000 factory workers in China, as opposed to 282 in Germany.
But times are changing, and fast. Labour and raw material costs are increasing in China due to environmental concerns and resource limitations, and other low-cost rivals have emerged. China’s position as the ‘world’s factory’ is under threat. As a result, the Chinese government is now keen to forge ahead with an alternative development path, replacing outdated production facilities and investing in modern technologies based on the Industrial Internet of Things.
The automotive industry currently signals growing demand for process control to further improve the quality of production processes at the same time as reducing operating expenses. This industry is welcoming the age of Industry 4.0 euphorically.
As an innovation driver, the industry is already implementing changes in the fields of automation, data interchange and production technologies with a view to benefiting from the resulting opportunities.
Safety-critical bolting is already monitored and analyzed; the data recorded is used for process optimization. Sensors record process data, with real-time transmission to higher level databases.
Powered by the Internet of things, Industry 4.0 promises automobile component suppliers significant effects at low cost. Steadily progressing digitalization offers this sector a tool for better reactions to growing market pressures. Key factors are reductions in system downtimes, improved productivity through automation and resource optimization and reduced maintenance expenses. Industry 4.0 allows agile processes, improves competitiveness and promises new sales opportunities.
At component production plants, Industry 4.0 implementation offers considerable potential, especially in predictive maintenance. Continuous recording and analysis of process data allows plant and system failures to be predicted, inefficient developments to be corrected and productivity to be improved.
Aerospace is a fantastic and extremely demanding industry, often synonymous with highly skilled personal and cutting-edge technologies. But with a production characterized by relatively small volumes, long cycle times, large components and high variability in the production processes, this industry offers specific challenges when it comes to the dissemination of smart tools and solutions.
As volumes continue to grow with people travelling more & more, all major OEMs need to increase the overall process efficiency, limit quality costs and cycle times, and exclude human factors as a source of error. With intelligent software and digital networking, assembly tools can now make a key contribution. They offer far greater flexibility and can be fully linked both to each other and to manufacturers’ production and quality systems.
Customers within the General Industry sector want innovative, unique, high quality and cost effective products. There is strong competition within the GI market that offer similar products with shorter product life cycles due to new technical advances. Therefore, there are high demands on the GI sector for rapid production of new innovative products for the market. We achieve this by completely digitalizing the product development life cycle. This in turn allows us to provide customers accurate traceability, quality control, and cost effective new products. When digitalizing the product life cycle, a complete digital data model is required. To meet these requirements industrial companies rely on intelligent and adaptable manufacturing. The vast range of products are embedded with systems, sensors, and actuators that are all linked to one another via the internet.
The Desoutter 4.0 white paper aims to present you the Desoutter vision, helping you to accelerate your transformation through Industry 4.0.
Desoutter 4.0 offers you much more than a unique solution, providing you connected products and experience. Boost now your up-time, your flexibility and your productivity by downloading the Desoutter 4.0: Accelerate your transformation white paper.
I have worked with Desoutter since 2012, when we first started using the E-LIT series battery assembly tools on the Toyota Prius production line. I think that implementing Industry 4.0 in our factory will improve communication between different solutions. We look to achieve a good production environment that is easy to manage, has great quality control and simple reporting procedures.
I believe that Desoutter’s Industry 4.0 solutions help facilitate communication between different tools, as well as external solutions, to improve the production process. At the moment, we are using Desoutter’s E-Pulse tools on our assembly line, as their high speed and low torque reaction meet our needs. In the future, we plan to use wireless tools in as many applications as possible. In the ideal scenario, we will have all battery tools communicating with each other as well as with the plant ERP.
We use Desoutter’s tools and fastening solutions in our trim and final assembly workshops at our Changshu plant. At the moment, we are installing Desoutter’s PivotWare process control system solutions in strategic areas. They help solve various complex manufacturing requirements, which enables our operators to focus on getting difficult processes right every time, improving quality. For us, industry 4.0, or China 2025, is the next step in improving connectivity.
We want to connect our equipment seamlessly to create more efficient manufacturing systems that help us create better products and meet customer requests more quickly. We plan to make our second trim and final assembly facility an intelligent workshop.
Desoutter are helping us create a fully connected tooling network, where we can instantly access the performance data of our tools and fastenings to identify and resolve potential problems in advance.
At Hella Autotechnik, we design new processes and make them a reality, as well as improving existing processes. We started working with Desoutter back in 2007, when we were looking for advanced technologies to improve our production processes. Desoutter proposed tailored and innovative solutions to help us achieve our objectives. We believe that Industry 4.0 is an excellent opportunity for us to reinforce our manufacturing competencies and leverage the benefits of these technologies, helping us to develop and manufacture products faster, cheaper and with greater accuracy.
We are preparing to introduce Desoutter’s Smart Start service offer , turnkey installation tool, which is very useful, as well as battery tools for improved flexibility and mobility.
I am in charge of tools maintenance at Honda’s manufacturing plant in Bangkok. We have worked with Desoutter since 2010, when we first started using Desoutter’s oil pulse tools on the assembly line. At the moment, we are using Desoutter’s solutions together with battery tools to optimize the flexibility of the assembly process. We are focused on reducing time to market and plan to increase the use of automation on our assembly lines and improve the operator interface in the near future.
I believe that Industry 4.0 will make us an attractive partner to work with, making us more efficient and responsive to customization demands. I see Desoutter as an innovative company taking an active role in the implementation of Industry 4.0 in Thailand.
I started working with Desoutter over seven years ago when we purchased Desoutter’s solutions to use when tightening the expansion valves and pipes on the evaporator assembly line. At the Valeo plant in Thailand, we are already implementing Industry 4.0.
We have an internal program which monitors the production site. When an alarm is raised, we are alerted immediately and can check the source using a computer or a mobile phone, without the need to visit the site. In the future, we hope to implement Industry 4.0 technologies throughout the factory, as this will improve profitability. We are especially interested in the wireless tools and new innovative assembly solutions Desoutter is developing. We expect Desoutter’s solutions to be user friendly, easy to access and enable data collection whenever the user wants it.
With its reliable tools and innovative assembly solutions that help us improve productivity, I believe Desoutter is one step ahead in the assembly market. We’ve used Desoutter’s small manual drilling machines for over a decade and for the past three years we have used the Seti-Tec range of electric drilling tools, particularly the Automatic Drilling Units.
We have now reached the validation phase, testing Desoutter’s Industry 4.0 solutions including geopositioning, QR code readers, PivotWare process control systems and new software. The objective is to get the operators, the HMI and the tools communicating together.
Ford has used Desoutter’s products at its plant in İnonu, Turkey, for a very long time and I have been working with these tools since I joined the company seven years ago. We manufacture motors for trucks and commercial vehicles and embracing Industry 4.0 is very important for us, as it enables us to optimize the efficiency of our production lines and secure the production processes. We are currently using Desoutter’s barcode control with advanced control program and all our tool units are connected to CVI NET WEB controllers for traceability.
Although Industry 4.0 implementation will take some time, we are moving towards it gradually. In this regard, we think that Desoutter’s PivotWare process control solution has great potential.
We have worked with Desoutter since 2010 and are currently using their CVI NET WEB controllers to provide real-time data traceability in many of our plants across China. Desoutter’s smart tools and database prompt us to carry out proactive maintenance regularly, to optimise plant availability.
A digital factory is a necessary precondition for achieving a smart factory. As part of our Industry 4.0 strategy, we are collecting A class data in our final assembly plants in order to optimise the assembly process. The next step is to invest in machine automation and cobot technology.
I am responsible for implementing our company’s manufacturing and engineering plan, a key driver of which is improving productivity. We are currently using Desoutter’s solutions, together with a process control program we have developed in-house, to provide traceability in our critical operations.
I think that SMART factory and industry 4.0 are the way forward for sharing data, improving connectivity and making it easier to monitor and control different applications. We don’t yet have a plan for company-wide Industry 4.0 adoption, but we’re working on it! We are aware of Desoutter Industry 4.0 solutions, having worked with the Korean Desoutter team for several years.
The company was already using Desoutter’s tightening solutions successfully when I arrived. We have continued the implementation of assembly solutions and are currently rolling out the operator guidance system PivotWare developed by Desoutter. I see Industry 4.0 among other aspects as the ability to control the entire production process through integrated communication between tools, machines and operators, using digitalization to enhance the exchange of data.
The implementation in our assembly lines of Desoutter tightening systems allowed us to control and trace key process steps. However, the integration of PivotWare is a major steps towards Industry 4.0. It gives the operator immediate access to all necessary technical information to fulfill its production order and guaranty the correct execution of all process steps. We now consider this as the basis to maintain the trust of our customers.