Industry 4.0

Ensure your manufacturing systems and processes are safe, secure, reliable and efficient

Why is Industry 4.0 Important To your business?

Industry 4.0 is the merging of physical and digital worlds through cyber-physical systems and cloud computing to automate tasks intelligently. The Internet of Things (IoT), Data Analytics, Intelligent Automation and Robotic Technologies are enabling the deployment of smart, data-driven manufacturing solutions that improve efficiency and quality, boost productivity, accelerate the speed to market and enable the development of new services.

Industry 4.0 is about hyper connectivity beyond the shop floor and factory environment, where automation and interaction between devices and systems takes place seamlessly throughout the value chain, integrating the entire product life cycle and across all relevant stakeholders (suppliers, customers, partners).

Digitalisation breaks down today’s walls of traditional, siloed steps in the manufacturing space and supply chain to an integrated ecosystem that is transparent to all parties involved. This in turn empowers companies to act fast and effectively in bringing in their offerings into the market, but also enables them to respond to and even predict disruptions in the value chain, adjusting in real time as conditions change. 

Evolution of Industry from 1.0 to 4.0

The 4th Industrial Revolution takes the way we are producing products, offering services and consuming products on the next level. Consumer centric manufacturing with its mass customisation or lot size one and just in time delivery decentralised, flexible and autonomous production facilities. Industry 4.0 envisages a highly connected factories network and integrated value chain with humans shifting their focus from day-to-day operations to more strategic, analytical tasks.

What is the impact of Industry 4.0? 

Impact on society:

  • Empowered and informed consumers have access to real-time info and demand customised experience. The connected consumer today influences the supply chain significantly.
  • Revolutionise all aspect of lives (the way we work and play) with increased efficiency and productivity.
  • Data security and privacy becomes more critical than ever.

Impact on Manufacturers:

  • Hyper-connectivity: Automation and interaction happen not only within the factory environment but along the entire value chain extending to suppliers and customers, address the entire product lifecycle
  • Speed and flexibility / Hyper-personalisation: Individualised mass production is now possible without compromising on cost, quality or speed.
  • The new skillset for workforce require new aspects in education programmes, but also much more continuous training as technology cycles shorten and hence corresponding capabilities change.

COMMON CHALLENGES MANUFACTURERS FACE 

1. Lack of familiarity with Industry 4.0 concepts

Industry 4.0, the Industrial IoT or Advanced Manufacturing, there is currently a conceptual diversity of future manufacturing in place, which many people do not understand or struggle to translate into their individual situation. This situation poses a strong hurdle to manufacturers and any stakeholder to take action with strategic impact. Understanding the key principles, concepts and technologies under Industry 4.0 is the crucial step to start, scale and sustain successfully the digital transformation.

2. There is a serious lack of uniform standards, regulations and forms of certification worldwide

There is no one global standard or technical solution of ‘one size fits all” resulting in a very individual manner of addressing Industry 4.0. Another consequence is the numerous amounts of pilots based on good practice which ultimately cannot be scaled, as the confidence in the reliability and robustness of the solution falls short. Joint efforts are being undertaken by standardisation bodies, government agencies, industrial associations, trade unions, employer's associations and others, and, though continuously best practice on individual topics are be being developed, there is still a long way to a broad, consensus-based approach and methodology.

3. Lack a systematic approach to identify opportunities and high-impact initiatives

Besides a common framework, approach, and corresponding lack of compatible technical solutions, the financial impact of Industry 4.0 solutions is often not captured sufficiently so that the actual base for making the right decision on investments, does not reflect the true value and side effects of Industry 4.0 solutions.

WHAT INDUSTRY 4.0 SERVICES DOES TÜV SÜD OFFER?

TÜV SÜD launched a Industry 4.0 services portfolio to initiate, scale and sustain manufacturers’ transformation journeys effectively. The 3-step transformation journey: 1. Initiation, 2. Solutioning, 3. Operation.

With our framework, we can help companies to formulate an Industry 4.0 roadmap that will be customised according to their strengths and challenges. TÜV SÜD partners with clients throughout their transformation, offering advice and guidance on how to fill gaps, Industry 4.0 roadmaps and business cases for technology implementation, as well as the relevant technical solutions to ensure safe and secure operations. With this, companies can to take on technology that enables them to integrate seamlessly into their infrastructure.

Step 1: Initiation

Readiness assessment:

TÜV SÜD and the Economic Development Board in Singapore developed the Smart Industry Readiness Index (SIRI) to help companies start, scale and sustain their transformation initiatives. The complex nature of Industry 4.0 requires a comprehensive consideration entailing Process, Technology and Organisation.

These 3 building blocks are based on 8 pillars: operations, supply chain, product lifecycle, automation, connectivity, intelligence, talent readiness and structure & management. The 8 pillars are then transferred in 16 Dimensions which are actually evaluated.

The result is a defined assessment of the organisation’s current level of readiness, which serves as the basis for developing a roadmap and its implementation plan to ultimately improve in their individual target functions: quality, productivity, speed and flexibility

Gap analysis:

Moving systematically from present state to future state is being realised by combining the current assessment result, the company’s revenue cost profile, and its relevant Key Performance Indicators. This brings the focus in a stringent way to the key areas where to shift the focus on and ultimately invest in.

Step 2: Solutioning

Roadmap:

Define high impact initiatives with phases, targets, costs and timeline mapped out

Best practices for roadmapping

Evaluating the business case:

Determining the importance of each initiative based on cost, risk and benefit including a cost-benefit matrix and deploying the right Key Performance Indicators to come up with the true value of Industry 4.0 solutions.

Technical Solutions:

Based on the outcome of the Initiation step deploying the Smart Industry Readiness Index, the gap analysis, the roadmap and cost-benefit-analysis, the right solutions and vendors are being identified

Step 3: Operation

Implementation and validation

Initiatives are implemented, and progress is monitored. Performance is evaluated to ensure continuous improvement.

Data analytics and process know-how is combined to target optimisation of the operations.


Your benefits at a glance

  • Increase efficiency and productivity, quality, speed and flexibilityBy implementing latest Industry 4.0 technologies that are safe, secure, reliable and interoperable.

  • Ability to scaleStarting with potentially small-scale solutions to manage the risk, scaling up enabled by applying best practice and adequate vendors.       

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