INDUSTRIAL REVOLUTIONS

Before the industrial revolutions, the machinery required for production had not
yet been discovered and everything was produced by hand. The areas where
people worked were limited to agriculture and animal husbandry. Later, three
great industrial revolutions took place with the substitution of muscle power with
machine power. The first industrial revolution, which created an evolution with
mechanical production facilities based on water and steam power, started at the
end of the 18th century. The second industrial revolution started at the beginning
of the 20th century and a new age was realized with the mass production of labor
based on electrical energy. The beginning of the third industrial revolution
coincides with the 1970s and with the automatic production feature based on
electronic and internet technology. differed from other industrial revolutions.
Industry 4.0, the fourth industrial revolution, continues today with the production
features of cyber-physical systems based on heterogeneous data and information
integration.

Figure 1. Industrial revolutions.

Figure 1. Industrial revolutions.

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First Industrial Revolution
The first industrial revolution, which took place between the 18th and 19th
centuries, was a time when agricultural and rural societies, mostly in Europe and
America, became industrial and urban. Before the first industrial revolution,
which began in Britain in the late 1700s, production was usually done in people's
homes, using hand tools or basic machinery. Industrialization gave rise to
powerful, special-purpose machinery, factories, and mass production. In the first
industrial revolution, which led to advanced systems in transportation,
communication and banking, the iron and textile industries were the most
important factors in the development of the steam engine. While industrialization
brought with it increased product volume and diversity and an improved standard
of living for some, it also resulted in brutal employment and living conditions for
the poor and working classes. A number of factors contributed to Britain's role as
the birthplace of the Industrial Revolution. found. First, it had large deposits of
coal and iron ore, which proved essential for industrialization. In addition,
England is a politically stable society. besides, it is the world's leading colonial
power; this meant that their colonies could serve as a source of raw materials and
a market for manufactured goods. During the first industrial revolution, many new
machines were invented. With the discovery of the rotating engine by the
Englishman James Harreaves in 1764, the production of spinning reels began.
While the inventions of James and others led to developments in the textile
industry, positive progress was also made in the iron-steel and logistics industries.
In the 1800s, the first commercial steamboat and the first steam locomotive that
could go on the railway were produced. These machines produced are the
evolution of the industry. and we are using modern versions of these machines
today.

Figure 2. The first steam engine

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Second Industrial Revolution
The main demonstrators of the second industrial revolution, which started towards
the end of the 1800s, were electric power and mass production. The second
industrial revolution, also called the technological revolution, was in many ways
a continuation of the first and there was direct continuity in many industries. In
1914 it was possible to see a direct impact of the second industrial revolution on
real wages and living standards, which differed markedly from 1870. In the
second industrial revolution, which continued until the end of the First World
War, we can talk about the invention of many things that are an integral part of
our today's lives. The most important of these is the having developed and
manufactured by Henry Ford. It was the first automobile to be owned. Karl
Friedrich Benz, the first automobile designer and inventor, is one of the most
important names of this period. In the second industrial revolution, the foundation
of modern shipping and ship industry was formed. In addition, the first
commercial telegraph and the first aircraft were used in this industrial revolution.

Figure 3. car uterine line

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Third Industrial Revolution
Industry 3.0, the digital revolution, started in the 1940s and continued until the
2010s. The two most important building blocks of this revolution have been
computers and the internet. In 1947, the first transistor, one of the most important
developments of this revolution, was produced. CNC (Computer Numerical
Controller), which is still in use today, was established in 1952. started production
of machines. In 1951, the first commercial computer, the LEO I, was released.
Following these developments, faster developments were experienced in terms of
digitalization and computerization, and the production of computers such as
Compaq, Dell, Toshiba and others began.

Figure 4. Overview of the 3rd industrial revolution

The Fourth Industrial Revolution

The concept of 'Industrial 4.0' first appeared in an article published by the German
government in November 2011 as a high-tech strategy for 2020. After
mechanization, electrification and knowledge, the fourth stage of industrialization
was called 'Industry 4.0'. in April 2013, The term 'Industry 4.0' was coined again
at an industry fair in Hannover, Germany, and it has quickly risen as the German
national strategy. Industry 4.0 will be a new industrial revolution that will have a
huge impact on international industry. In recent years, Industry 4.0 has been used
as a popular term to describe the trend towards digitization and automation of the
manufacturing environment. In other words, Industry 4.0 can be defined as the
increasing technical digitalization and automation of the production environment
and the creation of a digital value chain to enable communication between
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products and their environment. For this reason, the concept of digitalization
should be examined before the concept of Industry 4.0. According to Schwab,
digitization simply refers to automation. Also, the most visible reality of the
digital age is the "information products" that many new businesses produce with
zero storage and shipping costs. For example, some breakthrough tech companies
like Instagram or WhatsApp produce information products when they need low
capital to grow.

Figure 5. Robots welding body shells in Proton's plant in Tanjung Malim

Structure of Industry 4.0

• Industry 4.0 is a collective set of technologies and concepts of value chain

organizations. It is based on the concept of Cyber-Physical systems, the Internet
of Things and the Internet of Services. This structure makes a great contribution
to the formation of the vision of smart factories. Industry 4.0 generally consists of
the following 3 structures.
• Internet of Things
• Internet of Services
• Cyber-Physical Systems
• Within the scope of modular smart factories with Industry 4.0, it is aimed to
monitor physical processes with cyberphysical systems, to create a virtual copy
of the physical world and to make decentralized decisions. With the internet of
things, cyber-physical systems will be able to communicate and cooperate with

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each other and people in real time. With the Internet of Services, both internal and
cross-organizational services will be offered and evaluated by users of the value
chain.

Figure 6. Pillars of the fourth industrial revolution

Principles of Industry 4.0

• Industry 4.0 is based on 6 principles.

• 1) Interoperability: It involves the ability of cyber physical systems (eg

workpiece carriers, assembly stations and products) to communicate with each
other between humans and smart factories over the internet of things and internet
of services.

• 2) Virtualization: This structure is a virtual copy of smart factories. The system

consists of connecting sensor data with virtual plant and simulation models.

• 3) Autonomous Management: It is the ability of Cyber-Physical systems to make

their own decisions within smart factories.

• 4) Real-Time Capability: It is the ability to collect and analyze data. This

structure allows the understanding to be made quickly.

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• 5) Service Orientation: Cyber-physical systems, people and smart factory
services are offered over the internet of services.

• 6) Modularity: It provides a flexible adaptation system to smart factories for the

changing requirements of individual modules.

Figure 7. industry 4.0 technology pillars

Applicability of Industry 4.0 System

Production in the Industry 4.0 system, where the machines serve and
a system where they share information with products in real time.
is likened. German Artificial Intelligence Research Center (DFKI),
20 industrial and research partners, including Siemens In a small smart factory in
Kaiserslautern, Germany, it demonstrates how such a system would work in
practice. It uses soap bottles to show how products and manufacturing machines
can communicate with each other. Empty soap bottles have radio frequency
identification (RFID) labels on them, and these labels enable the machines to
recognize the color of the bottles. this system Thanks to this, it is possible to store
the information transmitted by a product via radio signals in a digital environment
from the beginning of production.

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Industry 4.0 Over Time
• Technological foundations include cyber-physical systems and internet
network. According to experts, Industry 4.0, in other words the fourth industrial
revolution, will complete its integration within 10 to 20 years and become
applicable by companies.

• In the United States, an initiative called the Smart Manufacturing Leadership

Coalition is also working on the future of manufacturing. This coalition consists
of a nonprofit organization, consortium of manufacturing practitioners, suppliers,
and technology companies, manufacturing, universities, government agencies,
and laboratories. The aim of the coalition is to provide industry stakeholders in
manufacturing to establish approaches to facilitate the adoption of production
intelligence, engage in R&D activities for platform and joint infrastructure
development, and form implementation and advocacy groups.

Figure 8. industry 1.0 t0 From 4.0 to the 4th industrial revolution

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 Figure 9. Towards Intelligent Environments based on the Internet of Things and
Services

Pros of Industry 4.0

• Among the companies that have already adopted the Industry 4.0 vision
Siemens Industry Sector evaluates the entire value chain
and automation technologies for all management processes, communication
and provide an integrated process with wireless information integration
is carrying out its work.

• Modern information and communication such as Cyber-Physical Systems,

Cloud Computing
technologies from the manufacturing sector for efficiency, quality and flexibility
will be integrated into the systems to increase
analysis will provide an advantage in the competitive environment.

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Industry 4.0 Challenges
• 1-) This is enough to accelerate the march towards the new industrial revolution.
There is a lack of skills and knowledge. Big German like Siemens, Bosch
companies are the leading names in this process with years of experience.
they are in position. By equipping their knowledge with the latest technology
They will be among the names that keep up with the Industry 4.0 era the fastest.

• 2-) Industry 4.0 means a decrease in labor demand. Therefore

It poses a redundancy threat in some departments in institutions.

• 3-) Industry 4.0 in companies that keep up with the rhythm of the third industrial
revolution
There is a general air of reluctance.

What Will Be the Effects of Industry 4.0?

• Machinery with systems that pass from worker power to technology control.
control will increase.

• Due to automatic systems, the required workforce will be reduced.

• Its impact on socio-economic working life will be felt.

• The industry gains a different value and provides this integration in the market.
will reach a large share.

New Needs Emerging with Industry 4.0

Make your production most profitable by adapting to the New Industrial
Revolution. all digitalization processes of a company that aims to bring complete
the production strategies with the goal of full automation. It means that its
development is fully compatible with Industry 4.0. It must be said that he did not
come. The whole of automation systems; a seamless reporting system between
machines, people and products provides. But still, traditionally based on top-down
employee model business management, which is advancing with control systems,
has also become the language of new control. must prevail

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 Conclusion

Today's economic system is constantly changing to maintain its continuity. needs

change and development. Rapid population growth and the problems experienced
in resource use and the changing world, brings with it innovations and changes.
So the world is growing and competition is increasing. In addition to efficiency
in production, quality is also vital. knows. This situation includes technological
progress, robotization or Industry 4.0. entails such approaches. With less
manpower shrinking factory areas, increasing product variety and quantity, rapid
release of products to the market, production times This phase will have important
returns in terms of shortening and increasing quality. Is considered.

What is SCADA ?
When you work in such fields as the oil and gas industry or the utilities industry,
there’s a significant chance that you will encounter a SCADA system while on
the job. These systems are essential for the monitoring and control of various
pieces of equipment that are designed to handle time-sensitive and critical events.
While there are many different types of SCADA software, each type comes with
similar features. Whether you own an industrial company or are a key manager at
one, you’ll likely want to know more about SCADA systems and how they work.
While this software is designed to run in the background, there are times when a
problem could develop with the software, which is why it’s important to
understand what SCADA is and how it works.

Figure-10

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Functions
The core functions of SCADA include:
-System monitoring
-Automated control of industrial processes and machines
-Data collection and analysis
-Event and Alarm Notifications
-Reporting

Figure-10. A Basic SCADA Diagram

So what does SCADA do?

Operators monitor and control the operation of a process thanks to SCADA
systems. They are used in industrial processes, telecommunication systems,
transportation sector, control of power plants. SCADA systems can control
processes that number in the hundreds of thousands . SCADA systems, in
summary; These are applications that enable instant monitoring and control of
the production and inspection process and the system elements involved in this
process, which can achieve the targets set in the controlled system with the least
cost

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 Figure-10. Example display screens for Siemens WinCC SCADA system –
representative photo

What are the Usage Areas of SCADA Systems?

The main purpose of industrial automation systems is to prevent human errors by

minimizing the manpower used in the production phase and to increase product
quality and speed by providing a certain standardization. SCADA systems enable
remote communication, make it easier to intervene especially in hard-to-reach and
long distances, and provide economic advantages (Gülle, 2004). Today, such
systems are applied in energy production facilities, water storage and
transportation processes, natural gas distribution lines, transportation and
construction sector, security and banking systems, feed production and air
conditioning . Today, SCADA system is applied in almost every area where
automation is used. There are many reasons for this frequent use. E.g; In the
networks where SCADA system is used, some situations that are dangerous for
human life have disappeared. In addition, it is possible to easily get information
about the process monitored with the SCADA system and to intervene in the
system remotely by finding faulty elements in case of malfunctions. Since the
SCADA system works in line with the demands of the user, the system to be
controlled will be more reliable and the number of users will be less. One of the
advantageous features of this system is the ability to receive reports. The historical
and instant values of the system controlled by using the report feature can be taken
as a report. One of the important features of SCADA is that it can give an alarm
(warning). When the set values change, the user is informed thanks to the alarm.
All these advantages have enabled the SCADA system to be used in many areas

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today. At the same time, manufacturers have always sought to provide their
customers with reliable, more affordable and useful systems. SCADA is highly
preferred because it is one of the systems that fully meets these demands.

The sectors where SCADA is mainly used are shown below :

-Natural gas and oil pipelines

-air pollution control
-traffic control
-electricity generation systems
-automotive industry
-food industry
-chemical industry
-building automation
-Process plants

Figure-11. Example SCADA Screen Drawing

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What are the Advantages of SCADA?
In today's world where technology is developing rapidly, automatic control
systems are also developing rapidly in parallel. A brief review will be presented
about automatic control systems, which are used in all advanced industrial
societies and have started to become widespread in almost every field in our
country. The fact that industrial automation systems are indispensable in modern
production processes is due to high efficiency and quality production, and the fact
that the elements controlling these systems are both cheap and fulfill the desired
tasks. Thus, it not only increased the work speed and production quality, but also
reduced industrial accidents and work errors. Due to such reasons, PLC and
SCADA systems have become the most preferred systems in the industry in
production processes . Automation systems consisting of many controllers,
especially PLC; In the automation systems and modernization of factories, in the
heating, cooling and air conditioning automation of indoor spaces, in elevator
control panels, in the management of energy distribution networks, in the
automotive industry, in fermentation systems, in the food, agriculture and
livestock sectors, at points where precise dosing is required such as paint, textile,
chemistry and pharmaceutical industries. ; temperature, pressure, flow, velocity,
weight etc. They are widely used in places such as measuring, displaying and
keeping the desired tolerance value of physical parameters, comparing, reporting
and storing process data, and remote monitoring and control of industrial facilities

Figure-12. SCADA Diagram Example System with Main Components

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To establish the necessary structure for automatic control systems used in almost
every area where it is desired to increase the quality and efficiency of the
produced product, with minimum cost, as explained above; By enabling data
communication between the production processes of the enterprises, it
contributes to a higher level of management and to reach the planned targets
with maximum efficiency.

What is the Structure of the SCADA System?

The structure of the SCADA system consists of field equipment, recognized
MTUs such as central main unit, RTUs called remote monitoring and control
unit and communication line.

Figure-12. SCADA System Architecture

How Can SCADA Help You?

Applying a SCADA system in your facility can help decrease production waste
and boost overall efficiency by providing useful production insights to operators
and management. The information derived from a SCADA system can facilitate
data-driven decisions and lead to increased output, reduced costs, and greater
control of your processes. Another benefit of SCADA is instant notification and
automated response to system alarms. With the immediate knowledge of issues
in the production process, operators and back-up systems are able to respond
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quicker to reduce equipment downtime and wasted product. At Process
Solutions, we have a team of certified SCADA engineers that work with our
clients to develop custom systems to match any manufacturing environment. For
more information about SCADA software, or to request a demonstration, please
contact us below to discuss your requirements

‘‘It should be noted that; There is never 100% security. For this reason, after
all security protocols are put into use, a penetration test must be made, and all
vulnerabilities must be fixed after revealing the vulnerabilities in the system.
Having the penetration tests done periodically with different companies and
closing the gaps will greatly reduce your security problems.

Thanks
Hussain Hakimzada

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