Industry 4.0

How will Industry 4.0 impact manufacturers?

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 such as suppliers, customers and 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 offers speed and flexibility when bringing their offerings to market; while enabling hyper-personalisation as individualised mass production becomes possible without compromising on cost, quality and speed. However, the workforce will need to develop new skillsets and undergo continuous training to address changing requirements and shortened technology cycles.  

Manufacturers’ challenges

1. Unfamiliarity with Industry 4.0 concepts

Industry 4.0, the Industrial IoT or advanced manufacturing; there is currently a conceptual diversity on future manufacturing, which many people do not understand or struggle to translate into their individual situation. This situation poses a big hurdle to manufacturers and any stakeholder who would like 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 successfully sustain the digital transformation process.

2. Lack of global uniform standards, regulations and certifications

As there are no global standards or “one size fits all” technical solution; Industry 4.0 has been addressed in an individual manner. Numerous amounts of pilots based on good practice have been conducted but could not be scaled as the solution fall short in terms of reliability and robustness. Joint efforts are now being undertaken by standardisation bodies, government agencies, industrial associations, trade unions, employer's associations and others but there is still a long way to a broad, consensus-based approach and methodology even though best practices on individual topics are developed continuously.

3. Inability to identify and measure opportunities and high-impact initiatives for investment

Financial impact does not reflect the true value and benefits of Industry 4.0 solutions. A systematic approach is required to facilitate investment decisions.

What Industry 4.0 services does TÜV SÜD offer?

TÜV SÜD Industry 4.0 services help manufacturers to initiate, scale and sustain their transformation journeys through the following 3-steps:  

Step 1: Initiation

The initiation step aims to create a baseline and provide clients with a deep understanding of Industry 4.0

• Readiness assessment: The Smart Industry Readiness Index (SIRI) was developed 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.
• 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 rigorously streamlines the key areas to focus on and ultimately invest in.

Step 2: Solutioning

Based on the results of Step 1; TÜV SÜD works with clients to on the following:

• Customised roadmap: Based on best practices, we work with you to define high impact initiatives with phases, targets, costs and timeline mapped out
• Business case evaluation: Determine the importance of each initiative based on cost, risk and benefit including a cost-benefit matrix and deploying the right key performance indicators to understand the true value of Industry 4.0 solutions
• Technical solutions: Identify the right solutions and vendors based on the outcome of the Initiation step

Step 3: Operation

In the last step TÜV SÜD works with clients to ensure that smooth integration of Industry 4.0 concepts and technologies during operations through the following:

• Support for implementation and validation
• Ensure 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.

Global manufacturers choose TÜV SÜD as their Industry 4.0 technical advisor

TÜV SÜD is committed to supporting companies harness the potential of Industry 4.0 and accelerate the transformation of industrial sectors. To date we have completed over 200 assessments of multinational corporations and small, medium sized businesses. By working with us you get expert guidance on how to take the first steps in your transformation journey and implement Industry 4.0 technologies that are safe, secure and reliable.

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