Industry 4.

0 in Mechanical Engineering

Course : Industry 4.0 Technologies in Mechanical Engineering

Lecturer : PhD Tran Quang Phuoc
 Industry 4.0 in Mechanical Engineering

Assessment

1. Attend the class, problems. 20%

2. Project + Presentation. 30%
3. Final Exam. 50%
 Industry 4.0 in Mechanical Engineering

References:
[1] Klaus Schwab, The Fourth Industrial Revolution, World Economic Forum, 2016.
[2] Elena G. Popkova, Yulia V. Ragulina, Aleksei V. Bogoviz, Industry 4.0: Industrial Revolution of the 21st
Century, Springer International Publishing, 2019.
[3] Sunil Pathak, Intelligent Manufacturing, Springer, 2021.
[4] Jongbae Kim; Roger Lee, Data Science and Digital Transformation in the Fourth Industrial Revolution,
Springer International Publishing, 2021.
[5] Carlos Toro, Wei Wang, Humza Akhtar, Implementing Industry 4.0: The Model Factory as the Key
Enabler for the Future of Manufacturing, Springer, 2021.
[6] Ana Landeta Echeberria, A Digital Framework for Industry 4.0: Managing Strategy, Palgrave
Macmillan, 2021.
[7] Hajjaj, Sami Salama Hussen, and Kisheen Rao Gsangaya. The Internet of Mechanical Things: The IoT
Framework for Mechanical Engineers. CRC Press, 2022.
[8] Chaudhary, Gopal, Manju Khari, and Mohamed Elhoseny, eds. Digital Twin Technology. CRC Press,
2021.
[9] Rajkumar, Raj, Dionisio De Niz, and Mark Klein. Cyber-physical systems. Addison-Wesley
Professional, 2016.
 Industry 4.0 in Mechanical Engineering

Industry 1.0
 Industry 4.0 in Mechanical Engineering

Industry 1.0
 Industry 4.0 in Mechanical Engineering

Industry 2.0
 Industry 4.0 in Mechanical Engineering

An Austrian railway in 1895

 Industry 4.0 in Mechanical Engineering

Benz Patent-Motorwagen, first The 1910 Ford Model T

production automobile, first built in 1885
 Industry 4.0 in Mechanical Engineering

Industry 3.0 (1947–Present)

1969–1989: Invention of the internet, rise of home
computers

1989–2005: Invention of the World Wide Web, mainstreaming

of the Internet, Web 1.0

2005–2020: Web 2.0, social media, smartphones, digital TV

The transistor was invented in 1947, and became

a key component of electronic devices.
Industry 4.0 in Mechanical Engineering
Industry 4.0 in Mechanical Engineering

Chapter 1 Introduction
 Industry 4.0 in Mechanical Engineering

Content
1. What Is Industry 4.0

2. Industry 4.0 Conception

3. Industry 4.0 Components

4. Industry 4.0: Design Principles

5. Impact of Industry 4.0

 Industry 4.0 in Mechanical Engineering

What Is Industry 4.0

- Industry 4.0 is a collective term for technologies and concepts of value chain
organization.
- The term “Industry 4.0” was introduced in Germany in 2011,

- The term “Industry 4.0” is used for the industrial revolution taking place currently
 Industry 4.0 in Mechanical Engineering

Definition of Industry 4.0

Industry 4.0 is a collective term for technologies and concepts of value chain
organization. Within the modular structured smart factories of Industry 4.0,
CPS monitor physical processes, create a virtual copy of the physical world
and make decentralized decisions. Over the IoT, CPS communicate and
cooperate with each other and humans in real time. Through the IoS, both
internal and cross-organizational services are offered and utilized by
participants in the value chain.
 Industry 4.0 in Mechanical Engineering

What Is Industry 4.0

- Industry 4.0 is multifaceted. It includes screws communicating with assembly robots, self-driving
forklifts stocking high shelves with goods, and intelligent machines coordinating independently
running production processes. In Industry 4.0, people, machines and products are directly connected
with each other (Platform Industry 4.0).
- Industry 4.0 refers to the intelligent networking of machines and processes in industry with the
help of information and communication technologies (ICT). There are many ways for companies to
use intelligent networking.
+ Flexible production: Many companies use a step-by-step process to develop a product. By being
digitally networked, these steps can be better coordinated and the machine load better planned.

+ Convertible factory: Future production lines can be built in modules and quickly assembled for
tasks. Productivity and efficiency will be improved; individualized products can be produced in
small quantities at affordable prices.
 Industry 4.0 in Mechanical Engineering

• Customer-oriented solutions: Consumers and producers will move closer together. The customers
themselves can design products according to their wishes—for example, sneakers designed and tailored
to the customer’s unique foot shape. At the same time, smart products that are already being delivered
and in use can send data to the manufacturer. By using these data, the manufacturer can improve his or
her products and offer the customer novel services.
• Optimized logistics: Algorithms can calculate ideal delivery routes; machines independently report
when they need new material—smart networking enables an optimal flow of goods.
• Use of data: Data on the production process and the condition of a product can be combined and
analyzed. Data analysis will provide guidance on how to make a product more efficiently. More
importantly, there is a foundation for completely new business models and services. For example, lift
manufacturers can offer their customers “predictive maintenance”: elevators equipped with sensors that
continuously send data about their condition. Product wear can be detected and corrected before it leads
to an elevator system failure.
• Resource-efficient circular economy: The entire life cycle of a product can be considered with the
support of data. The design phase will be able to determine which materials can be recycled
(Platform Industry 4.0).
 Industry 4.0 in Mechanical Engineering

What Is New in Industry 4.0?

Digitalizing production is gaining a new level of quality with global

networking across corporate and national borders. With IoT and machine-
to-machine communication, manufacturing facilities are becoming more
intelligent.
Industry 4.0 in Mechanical Engineering

What Is Industry 4.0

Industry 1.0 : Mechanization of manufacturing with
water and steam power.

Industry 2.0 : Mass production assembly line with

electrical power

Industry 3.0 : Automated production using

electronics, robotics and IT systems

Industry 4.0 : Autonomous decision making of cyber

physical systems using machine learning and big data
analytics
 Industry 4.0 in Mechanical Engineering

On the Path to Industry 4.0: What Needs to Be Done?

Implementing Industry 4.0 is a complex project: the more processes

companies digitalize and network, the more interfaces are created between
different actors. Uniform norms and standards for different industrial sectors,
IT security and data protection play an equally central role as the legal
framework, changes in education and jobs, the development of new business
models and corresponding research (Plattform Industrie 4.0).
Industry 4.0 in Mechanical Engineering
Industry 4.0 in Mechanical Engineering
Nine technology drivers
 Industry 4.0 in Mechanical Engineering

Industry 4.0 conception

In the twenty-first century, product life cycles are shorter and consumers demand more complex, unique
products in larger quantities. Both pose challenges to production.
+There are many indications that current practices in the utilization of resources are not sustainable, with a
consequent effect on production.
+The industrial sector is experiencing a paradigm shift, which will change production drastically.
+The traditional, centrally controlled and monitored processes will be replaced by decentralized control.
built on the self-regulating ability of products and work units that communicate with each other.
+The essence of Industry 4.0 is the introduction of network-linked intelligent systems to achieve self
regulating production: in this new workplace, people, machines, equipment and products will communicate
with one another.
+The goal is to ensure flexible, economical and efficient production. All parts of the production process
will communicate with all other parts via a central production control system.
In effect, products will control their own production, with virtual and actual reality merging during
production. Scheduling will be also controlled by communicating units. Factories will be self-regulating
and optimize their own operation.
 Industry 4.0 in Mechanical Engineering

Five Main Components of Networked Production

• Digital workpieces Each workpiece knows the dimensions, quality requirements and order of its own
processing.
• Intelligent machines Intelligent machines communicate simultaneously with the production control system
and the workpiece being processed, so that the machine coordinates, controls and optimizes itself.
• Vertical network connections
After processing the customer’s unique specifications for the product to be manufactured, the production
control system forward automated rules to the equipment. Essentially, the products control their own
manufacturing process, as they communicate with the equipment, devices and other workpieces on the
conditions of production.
• Horizontal network connections
Communication is realized not only within one factory, but throughout the whole supply chain, between the
suppliers, manufacturers and service providers. The main purpose is to enhance the efficiency of production
and to utilize the resources in a more economical way.
• Smart work pieces
The product to be manufactured senses the production environment with internal sensors and controls and
monitors its own production process to meet the production standards; it can do so because it can communicate
with the equipment, as well as with the components already incorporated or about to be incorporated.
 Industry 4.0 in Mechanical Engineering

Framework of Industry 4.0

 Industry 4.0 in Mechanical Engineering

Big data and analytic

The first of the nine pillars is big data and analytics. Analytics based on large
data sets have recently emerged in the manufacturing world; such analytics
optimize production quality, save energy, and improve equipment service. In
the Industry 4.0 context, the collection and comprehensive evaluation of data
from many different sources (production equipment and systems as well as
enterprise- and customer-management systems) will become a standard
support in real-time decision-making.
 Industry 4.0 in Mechanical Engineering

Autonomous Robots

Manufacturers in many industries have long used robots to tackle complex

assignments, but robots are evolving for even greater utility. They are
becoming more autonomous, flexible and cooperative. Eventually, they will
interact with one another and work safely side by side with humans and
learn from them. These robots will cost less and have a greater range of
capabilities than those used in manufacturing today.
 Industry 4.0 in Mechanical Engineering

Simulation

In the engineering phase of production, three-dimensional (3-D) simulations

of products, materials and production processes are already used, but in the
future, simulations will be used more extensively in plant operations as well.
These simulations will leverage real-time data to mirror the physical world in
a virtual model, which can include machines, products and humans. This will
allow operators to test and optimize the machine settings for the next product
in line in the virtual world before the physical changeover, thereby reducing
machine setup times and increasing quality.
 Industry 4.0 in Mechanical Engineering

Horizontal and Vertical System Integration

Most of today’s IT systems are not fully integrated. Companies, suppliers, and
customers are rarely closely linked, nor are departments such as engineering,
production and service. In addition, functions from the enterprise to the shop
floor level are not fully integrated. Even engineering itself—from products to
plants to automation—lacks complete integration. However, with Industry 4.0,
companies, departments, functions and capabilities will become much more
cohesive, as cross-company, universal data-integration networks evolve and
enable truly automated value chains.
 Industry 4.0 in Mechanical Engineering

Industrial IoT
Today, only some of a manufacturer’s sensors and machines are networked and
make use of embedded computing. They are typically organized in a vertical
automation pyramid in which sensors and field devices with limited intelligence
and automation controllers feed into an over arching manufacturing process
control system. However, with the Industrial IoT, more devices (sometimes
including even unfinished products) will be enriched with embedded computing
and connected using standard technologies. This will allow field devices to
communicate and interact both with one another and with more centralized
controllers, as necessary. It will also decentralize analytics and decision-
making, enabling real-time responses.
 Industry 4.0 in Mechanical Engineering

Cybersecurity

Many companies still rely on unconnected or closed management and

production systems. With the increased connectivity and the use of the
standard communications protocols accompanying Industry 4.0, the need to
protect critical industrial systems and manufacturing lines from cybersecurity
threats increases dramatically. As a result, secure, reliable communications,
as well as sophisticated identity and access management of machines and
users, are essential. Several industrial-equipment vendors have joined forces
with cybersecurity companies through partnerships or acquisitions.
 Industry 4.0 in Mechanical Engineering

The Cloud

Companies are already using cloud-based software for some enterprise

and analytics applications, but with Industry 4.0, more production-related
undertakings will require increased data sharing across sites and company
boundaries. At the same time, the performance of cloud technologies will
improve, achieving reaction times of just several milliseconds. As a result,
machine data and functionality will increasingly be deployed in the cloud,
enabling more data-driven services for production systems. Even systems
that monitor and control processes may become cloud-based. Vendors of
manufacturing execution systems have started to offer cloud-based
solutions
 Industry 4.0 in Mechanical Engineering

Additive Manufacturing

Companies have just begun to adopt additive manufacturing, such as 3-D

printing, which they use mostly to prototype and produce individual
components. With Industry 4.0, these additive-manufacturing methods will
be widely used to produce small batches of customized products that offer
construction advantages, such as complex, lightweight designs. High-
performance, decentralized additive manufacturing systems will reduce
transport distances and stock on hand.
For instance, aerospace companies are already using additive manufacturing
to apply new designs that reduce aircraft weight, lowering their expenses for
raw materials such as titanium.
 Industry 4.0 in Mechanical Engineering

Augmented Reality

Augmented-reality-based systems support a variety of services, such as

selecting parts in a warehouse and sending repair instructions over mobile
devices. These systems are currently in their infancy, but in the future,
companies will make much broader use of augmented reality to provide
workers with real time information to improve decision-making and work
procedures.
 Industry 4.0 in Mechanical Engineering

Macro Perspective of Industry 4.0

 Industry 4.0 in Mechanical Engineering

Micro Perspective of Industry 4.0

Covers horizontal and vertical

integration within smart factories
and is also part of the end-to-end
engineering dimension.
 Industry 4.0 in Mechanical Engineering

Industry 4.0 Components

Cyber-Physical Systems (CPS)
Cyber-physical systems are “integrations of computation and physical processes. Embedded
computers and networks monitor and control the physical processes, usually with feedback loops
where physical processes affect computations and vice versa”.
The development of CPS can be divided into three phases.
+ The first generation of CPS includes identification technologies such as RFID tags, which allow
unique identification. Storage and analytics have to be provided as a centralized service.
+ The second generation of CPS is equipped with sensors and actuators with a limited range of
functions.
+ In the third generation, CPS can store and analyze data, are equipped with multiple sensors and
actuators and are network compatible.
 Industry 4.0 in Mechanical Engineering

Industry 4.0 Components

Internet of Things

- The integration of the IoT with the Internet of Services (IoS) in the
manufacturing process initiated the fourth industrial revolution.
- The IoT allows “things” and “objects,” such as RFID, sensors, actuators and
mobile phones, to “interact with each other and cooperate with their
neighboring ‘smart’ components, to reach common goals”.
 Industry 4.0 in Mechanical Engineering

Industry 4.0 - Design Principles

 Industry 4.0 in Mechanical Engineering

Industry 4.0 Design Principles

Interoperability

Interoperability means all CPS within a plant (workpiece carriers,

assembly station and products) are able to communicate with each
other “through open nets and semantic descriptions”
 Industry 4.0 in Mechanical Engineering

Industry 4.0 Design Principles

Virtualization

Through virtualization, CPS are able to monitor physical processes.

Sensor data are linked to virtual plant models and simulation models,
creating a virtual copy of the physical world. In the Smart Factory KL
plant, the virtual model includes the condition of all CPS.
 Industry 4.0 in Mechanical Engineering

Industry 4.0 Design Principles

Decentralization

The rising demand for individual products makes it increasingly

difficult to control systems centrally. Embedded computers enable
CPS to make decisions on their own. Only in cases of failure are
tasks delegated to a higher level.
 Industry 4.0 in Mechanical Engineering

Industry 4.0 Design Principles

Real-Time Capability

For organizational tasks, data must be collected and analyzed in real

time. In the SmartFactoryKL, the status of the plant and all its
equipment is permanently tracked and analyzed. Thus, the plant can
react to the failure of a machine and reroute products to another
machine
 Industry 4.0 in Mechanical Engineering

Industry 4.0 Design Principles

Service Orientation

The services of companies, CPS and humans are available over the
IoS and can be utilized by other stakeholders. They can be offered
both internally and across company borders. The SmartFactoryKL
plant is based on a service-oriented architecture, wherein all CPS
offer their functionalities in an encapsulated web service. As a result,
the product-specific process operation can be based on the
customer-specific requirements provided by the RFID tag.
 Industry 4.0 in Mechanical Engineering

Industry 4.0 Design Principles

Modularity

Modular systems can flexibly adapt to changing requirements by

replacing or expanding individual modules. Therefore, modular
systems can be easily adjusted to accommodate seasonal
fluctuations or changed product characteristics.
 Industry 4.0 in Mechanical Engineering

Industry 4.0 Servitization Framework

- The servitization literature commonly describes three categories of
services offered by manufacturing firms.
- Basic services are “outcome-focused on product provision,” e.g.,
spare parts.
- Intermediate services center on enhancing the product’s use and
condition, e.g., helpdesks or conditioning monitoring.
- Finally, advanced services are focused on the performance of the
product
 Industry 4.0 in Mechanical Engineering

Product Service-System (PSS)

- The concept of a PSS is a
special case of servitization. A
PSS can be thought of as a
market proposition that extends
the traditional functionality of a
product by incorporating
additional services.
- Here, the emphasis is on the
“sale of use” rather than the
“sale of product.”
 Industry 4.0 in Mechanical Engineering

Product Service-System (PSS)

1. Product: a tangible
commodity manufactured to be
sold.
2. Service: an activity (work)
done for others with an
economic value and often done
on a commercial basis.
3. System: a collection of
elements, including their
relations.
 Industry 4.0 in Mechanical Engineering

Product-Oriented PSS (PoPSS)

Product-oriented PSS refers to physical products surrounded by
product-related services whose aim is to improve the functionality
and performance of the product and/or to manage its life cycle
 Industry 4.0 in Mechanical Engineering

Use-Oriented PSS (UoPSS)

Use-oriented PSS are

aimed at offering the
maximum possible
availability of the
product to sell its
effective use rather
than its property rights
 Industry 4.0 in Mechanical Engineering

Result-Oriented PSS (RoPSS))

This might mean, selling the whole

management of some activities
(much like outsourcing), letting
customers pay-per-service unit
(e.g., per washed dress, instead of
per washing machine sold) or per
functional result (e.g., transporting
customer from point A to point B,
regardless of the time and fuel
involved)
 Industry 4.0 in Mechanical Engineering

Home works :
Study to use the software. Each group chooses 1 software, and each member chooses 1
topic to practice and make ppt report and video. --- Deadline: 2 weeks.
+ After 1 week, each group report about the software
+ After 2 weeks, individual person reports.
1- Factory IO “https://www.youtube.com/watch?v=XVKFa5S3-E4”
2- Automation studio “https://www.youtube.com/watch?v=274zEMXi3F8 “
3- Robot DK “https://robodk.com/examples#examples-extaxismilling”
4- Robo sim “https://www.youtube.com/watch?v=Zeg571L2sig”
5- Robo guide “ https://www.youtube.com/watch?v=neAFHplKu-Y”
6- Robot studio “ https://www.youtube.com/watch?v=ohePUt-NylU”
7- Visual component
8- workvisual
9- Vericut
10- 3D software ( Inventor, solidwork, creo .... Simulation )