INDUSTRY 4.

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Contents

1.0 Introduction.....................................................................................................................................2

2.0 Revolution of industrial Manufacturing Systems.............................................................................2

3.0 General Process Explanation...........................................................................................................3

3.1 Product Description.....................................................................................................................3

3.2 Process Description.....................................................................................................................3

4.0 Smart factory concept development...............................................................................................5

4.1 Inter- Relation between pillars....................................................................................................6

5.0 Pillar of Industry 4.0 – In the context of smart factory....................................................................7

5.0 Conclusion.......................................................................................................................................9

7.0 Reference......................................................................................................................................10

List of Figures
1. History of Industry revolution ………………………………………………………………………………………….........…2

2. D pillar Part …………………………………………………………………………………………………………………….............3

3. Traditional production line..............................................................................................................3

4. Industry 4.0 Production line............................................................................................................5

5. Process Flow Diagram between I4.0 pillars.....................................................................................6

List of Table

1. Bill of Material ………………………………………………………………………………………………………………………….1

pg. 1
2. Pillars in D pillar production …………………………………………………………………………………………….…7,8,9

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1.0 Introduction
Smart Factory is a new terminology in this new era of manufacturing industries. It is the
technological framework which is focused on smart manufacturing lines and machine intelligence is
to use the advanced information technology to support with process and product development
performance such as the Cyber Physical Systems (CPS) and Internet of Things (IoT), smart factories
and smart services (Yuanyuan Yin, 2019). The conceptual framework above enables us to
comprehend the scope and depth of the revolutionary influence that the current Fourth Industrial
Revolution must be expected to have (De Propris, L. and Bailey, D.,2020). The implementation of
industry 4.0 is not dependent on the size and complexity of the industry. But the part of lean
manufacturing and defect prevention. By the deployment of FIR, will help to have early prediction of
defect generation, auto production planning and re-ordering of raw material inventory, machine
maintenance and brake down alert, machine feedback communication and intelligence etc.
Numerous development approaches are connected to the phrase "Industry 4.0" and a variety of
meanings have been created. In general, the phrase refers to the fusion of physical and digital
production across all industries (Deuse, J, 2020).

2.0 Revolution of industrial Manufacturing Systems

In the late eighteenth century, the manufacturing industry took place the first revolution by the
innovation of steam engine from James watt. The second revolution took place by the establishment
of assembly line or conveyors assembly line by Henry ford automobile factory. Electronic automation
was the next revolution in manufacturing industry. The PLC/NC’s are integrated with mechanical

Figure 1: History of Industry revolution

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machines give logical memory for production system. The current manufacturing system is advanced
to cyber physical system, networking, physical processing. The industry 4.0 was introduced by
German government by 2011 with the ambition to lead supplier and industry towards industry 4.0.

3.0 General Process Explanation

3.1 Product Description
The sheet metals are joined through spot welding process for the manufacturing of integrated
chassis assembly for automobile and one of the main panel assemblies is considering for explaining
and demonstrating the importance of industry 4.0.

D – Pillar is a chassis assembly part of automobiles which is a vertical structural member at the back
of vehicle. It is a support beam for back door and general assembly’s such as tail lamp assembly,
petrol tank inlet assembly, rear wiper motor assembly. D pillar assembly is strong and durable to
uphold the rear impact collision.

D Pillar
Assembly

Figure 2 : D pillar Part

3.2 Process Description

The sheet metals are jointing by using spot welding process and fasteners are welding with sheet
metal to assemble other metal and non-metal parts of automobiles. For manufacturing D pillar
assembly, it is required a sequence of operation to assemble other child panels and fasteners at
different locations of main panel assembly. It important the orientation of panels at right angle and
location. The chance of part mix up is high so different assembly line was introduced for both left
hand side (LHS), and Right-hand side (RHS) assembly. Due to different variant production, the chance
of part mix up is also high which will lead major recalls. Now it was arrested by using different trolley
used for 2 variant and only one variant will produce at a time.

The production general process layout is defined in the given below figure: 2 It use 2 different
assembly line for LHS and RHS d pillar production. Consist of two spot welding machine and two
fasteners assembly machines. Operation 10 is the assembly of main panel and base rest panel and

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after it will move to assembly station 20 for the assembly of copper screws. The operation 30 is the
assembly of main panel with upper fleat and side door rest support and final operation for the
assembly of square bolt M10 at different location of panels.

Floor layout - D Pillar assembly line

r m b lytro lle y
M ain Pan e l tro lle y

r m b lytro lle y
Pan e l 1 tro lle y

Fastn easse

Fastn easse
Pan e l 2 tro lle y
OP 10 OP 20 OP30 OP40

Required panels are

supplied to welding
assembly line as batch
Gang Way
quantity using Kanban
feeding system.

OP 10 OP 20 OP30 OP40

r m b lytro lle y

The fixed quantity fastners will supply to

Pan e l 2 tro lle y
M ain Pan e l tro lle y

r m b lytro lle y
production line from stores based on
Pan e l 1 tro lle y

production schdule
Fastn easse

F astn easse

Figure 3: Traditional production line

The four panels will supply from stamping shop as batch using Kanban system. The fasteners issue to
production from stores based on production requirement at the beginning of production. The bill of
material is explained in the BOM list (table. 1)

Bill of material for D pillar assembly Light weighted assembly

Part Number Part Name Quantity Weight
10001 D piller main panel - LHS 1 2.80
10002 Base rest panel - LHS 1 0.89
10003 Upper Fleat - LHS 1 1.20
10004 Side door rest support - LHS 1 0.42
10005 D piller main panel - RHS 1 2.80
10007 Upper Fleet - RHS 1 1.20
10008 Side door rest support - RHS 1 0.42
23009 Copper screw - LT 4 0.10
24011 Square Bolt - M10 6 0.38

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 Table 1: Bill of material

4.0 Smart factory concept development

The main objective of a manufacturing system is to reduce wastage and made the production line
efficient and effective. It will results work standardization, zero defects, employee orientation, visual
management, elimination of bottleneck process etc. In order to compare Industry 4.0 approaches
with Lean production system methodologies, which do not specifically address Industry 4.0
characteristics, it is not appropriate to characterise Industry 4.0 approaches according to application
sectors, such as manufacturing or warehousing (Deuse, J, 2020).

more compact and efficient when it compares with the old layout. The use of manpower significantly
reduced two stations can run by single man. The fixtures are specially designed with datum
reference points, sensors which is connected to PLC’s.

Communities are beginning to undergo a big update, not merely in terms of technology, as a result
of industry 4.0. High levels of digitalization for all types of business processes are also necessary with
the advent of exponential technology, high speed, and big data processing capabilities. For a
complete vertical and horizontal integration of all business functions, from the executive level down
to the shop floor, supported by appropriate infrastructures, such as IoT, IIoT, RFID, CFS, and Cloud
(Leonilde Varela, 2019)
New Process line for D pillar assembly (Industry 4.0)

Fastners and child

panel assembly
(LHS)

Main panel and base

rest panel assembly
(LHS)

Main panel and base

rest panel assembly
(RHS)

Fastners and
child panel
assembly (RHS)

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 Figure 4 : Industry 4.0 Production line

Industry 4.0 offers opportunities that can be categorised into six main typologies: production
flexibility, which happens during the production of small lots; speed of serial prototypes; increased
output capacity; lower set-up costs and fewer errors and machine downtimes; higher product
quality and less rejected production; and customers' improved opinion of products (Büchi, G.,
Cugno, M. and Castagnoli, R, 2020).

4.1 Inter- Relation between pillars

Each pillar is connected to each other to fulfilment of pillars requirement. The 9 pillar inter-relation
is explained in the figure 5 – Process flow diagram between I4.0 pillars. The industrial Internet of
Things (IoT) enables constant connectivity between people and things while digitalizing all physical
systems to ensure transformative solutions that will serve as the cornerstone of next complex
business ecosystems (Fonseca, 2021). The Product and Process development data (Design &
Simulation data), Production data for the manufacturing of D- pillar will directly stored in cloud and
the big data analysis is conducted with the help of software and study, the statistical process control
tool used to understand the production process to take necessary actions.

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 Figure 5: Process Flow Diagram between I4.0 pillars

The system integration, help the production by the interconnections of machines and operator to
produce defect free D-Pillars which is store the data to cloud and the data is capture, storage,
distribution, management, and analysis the information and these datas are protected by cyber
security management system. The use of augmented reality in D pillar manufacturing process, which
helps the improve operators’ performance and efficiency by providing information to execute the
task with the help of AR’s, as it supports decision making.

Another important is between simulation, IoT, Robotics and System integration. These are
interconnected and it delivers productivity and quality performance in the production line. System
integration that is both horizontal and vertical, with cooperative scenarios for system integration
and real-time sharing. During the development stage, use virtual reality to understand the shopfloor
design and interconnection of machine to each other. Accordingly, it will help to deploy program
poka-Yokes in process line.

Robots enhanced with AI can support various manufacturing processes while lowering production
costs (‌Fonseca, L., Amaral, A. and Oliveira, J, 2021) can get the feedback from visual inspection and
weld quality testing centre. The data will be analysed, and improved feedback will give to robots to
adjust parameter from IoT. The integrated system is interlinked which can be able to transfer the
required data to right station easily. All production, Inspection, Testing data will be stored in cloud.

5.0 Pillar of Industry 4.0 – In the context of smart factory

Pillar Description Eliminated potential causes
In augmented Reality, the system
brings to use mobile devices,
through sight, sound, proximity,
glove, lens etc to take input for  Reduce Man Error.
Augmented
better monitoring of process line.  Accuracy in process setting
Reality
Real-time information will be  Better Fault Finding
provided by these technologies to
enhance decision-making and work
operations.
In this process the additive  Quality improvement
manufacturing system is deployed  Productivity improvement
Additive with robo arm to make studs and by avoiding stamping
manufacturing dimple in the main panel It will operation and stud
helps to avoid dislocation in the generation art weld
child part assembly assembly.

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 Pillar Description Eliminated potential causes
The advance robotics used in the
 The manpower utilized for
production line to pick and place
production reduced.
on one head and other head have
Advanced  The controlled process
the spot-welding gun. The
Robotics parameter will help to
parameters such as weld time,
enhance product quality
current, squeeze time, etc are
 Reduce downtime
controlled by using PLC's.
Robo's and fixtures are
interconnected to each other and
with central control unit. Any error
will recorded and alerted at central
 Operation miss will be
control unit, which means it have
completely avoided
connected with cyber system. So
System  Process parameter data
the data from the machine
integration storage will avoid process
(Process parameters) will directly
parameter variation and it
save in the system (Cloud). Some
can used for analysis
sensors like proximity, distance etc
used as poke yoke (error
proofing’s) to avoid defect
generation
The data analysis is penetrating to
manufacturing industry as a part of
artificial intelligence and machine
 Early prediction of
learning. As a result, it will help to
production faults
identify the defect generation at
Big data analysis  Can avoid big breakdown
early stage in manufacturing. Data
due to getting feedback
collection is possible at many
from machines
stages of the production process. If
a PCB is found to be flawed, their
production data may be retrieved.

The communication between  Data loose and recovery.

Cyber security machine and network has a lot of  Prime product and process
nodes. It can be interrupted, and data protection.

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Sl.No Pillar Description Eliminated potential causes
The communication between
machine and network has a lot of
nodes. It can be interrupted, and
the data can be looted. The  Data loose and recovery.
4 Cyber security simulation data, development data  Prime product and process
are relevant and protect. It is data protection.
necessary to protect factory from
cyber interruptions and IT
potential threads.
The data communication and
transfer are important in
production to avoid potential huge
losses. By using Cloud computing,
 Data access become easier
5 Cloud computing it will help to share the data to
and flexible.
required destinations at right time.
Hence it will help to take right
decision at right time and
accessibility to data.
It is the use of technology and
sensors in the machines and the
products. It this process layout the
fixtures are designed with
 Reduction in defect
proximity sensors, light sensors,
Internet of generation
6 distance sensors etc. It will give the
Things  Reduce internal failure
signal if the product is loaded in
cost.
wrong way, Child part does not fix
with fixture, Dislocation etc. The
machine will give feedback if the
process cycle get completed.

The use of stimulation during the

 Help to reduce appraisal
development stage, the layout
7 Stimulation cost, Internal and external
design and bottle neck process can
failure costs
be able to identify, and it will help

Table 2: Pillars in D pillar production

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5.0 Conclusion
The industry 4.0 take a lead role in manufacturing industry to transform the traditional
manufacturing system. Industry 4.0 help the manufacturers to improve the quality as well as
productivity. The communication channel between machines and human helps to reduce the barrier
and clear communication is passed through. The integrated approach of lean manufacturing and
adaptation of industry 4.0 give better results with respect to overall equipment efficiency. The
stimulation, virtual reality pillars will helps to reduce implementation cost (which is very huge) and
augmented reality, Robotics, system integration, more focused on prevention of defection. The
ideas of Industry 4.0 also include flexible manufacturing to enable customised production, real-time
data transmission, and horizontal and vertical integration of production systems. Such information is
essential for enabling various types of decision-making, including the prioritising of production
orders, task optimization, and other requirements, such maintenance tailored to each individual's
demands (Varela, L., Araújo, A., Ávila, P., Castro, H. and Putnik, G, 2019).

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7.0 Reference
Yin, Y., & Qin, F. (2019). A smart performance measurement approach for collaborative design in
Industry 4.0. Advances in Mechanical Engineering. https://doi.org/10.1177/1687814018822570

Simon, J., Trojanova, M., Zbihlej, J., & Sarosi, J. (2018). Mass customization model in food industry
using industry 4.0 standard with fuzzy-based multi-criteria decision-making methodology. Advances
in Mechanical Engineering. https://doi.org/10.1177/1687814018766776

Mittal, S., Khan, M. A., Romero, D., & Wuest, T. (2017). Smart manufacturing: Characteristics,
technologies and enabling factors. Proceedings of the Institution of Mechanical Engineers, Part B:
Journal of Engineering Manufacture. https://doi.org/10.1177/0954405417736547

De Propris, L. and Bailey, D., (2020), Industry 4.0 and regional transformation. Place of publication
not identified: Routledge.

Deuse, J., Dombrowski, U., Nöhring, F., Mazarov, J., & Dix, Y. (2020). Systematic combination of Lean
Management with digitalization to improve production systems on the example of Jidoka 4.0.
International Journal of Engineering Business Management.

Varela, L., Araújo, A., Ávila, P., Castro, H. and Putnik, G. (2019). Evaluation of the Relation between
Lean Manufacturing, Industry 4.0, and Sustainability. Sustainability, 11(5), p.1439.
doi:10.3390/su11051439.

Büchi, G., Cugno, M. and Castagnoli, R. (2020). Smart factory performance and Industry
4.0. Technological Forecasting and Social Change, [online] 150, p.119790.
doi:10.1016/j.techfore.2019.119790.

‌Fonseca, L., Amaral, A. and Oliveira, J. (2021). Quality 4.0: The EFQM 2020 Model and Industry 4.0
Relationships and Implications. Sustainability, [online] 13(6), p.3107. doi:10.3390/su13063107.

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