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OPM in Industry 4.0 (M5)

Industry 4.0 trends like the Industrial Internet of Things (IIoT) and Big Data can help organizations better understand issues like equipment downtime through the use of affordable sensors to collect and analyze machine data without physical monitoring. Cybersecurity also becomes more important as connecting IIoT devices to networks increases vulnerability, and maintaining documentation is critical as digital transformation occurs. Companies implementing Industry 4.0, like Bosch using sensors and analytics to increase output 10% and GE using augmented reality glasses to boost productivity 11%, are revolutionizing operations management.

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73 views3 pages

OPM in Industry 4.0 (M5)

Industry 4.0 trends like the Industrial Internet of Things (IIoT) and Big Data can help organizations better understand issues like equipment downtime through the use of affordable sensors to collect and analyze machine data without physical monitoring. Cybersecurity also becomes more important as connecting IIoT devices to networks increases vulnerability, and maintaining documentation is critical as digital transformation occurs. Companies implementing Industry 4.0, like Bosch using sensors and analytics to increase output 10% and GE using augmented reality glasses to boost productivity 11%, are revolutionizing operations management.

Uploaded by

Sagar
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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To better understand Industry 4.

0 trends and how they can help your


organization, please see the following examples:

 Industrial Internet of Things (IIoT). IIoT refers to the ability to


distribute intelligent devices to capture information from places, processes
or equipment that are not normally capable of communication. Consider
any manufacturing operation struggling with understanding downtime. If
their equipment is not intelligent or connected to a network, they’re
limited in what or how they can track downtime, other than operators
physically logging it on paper. Automation for the sake of gathering data
can be cost-prohibitive, until now—IIoT offers an increase of affordable
devices that can be dropped anywhere to capture and transmit data
directly into the cloud. From there, powerful analytics tools can store and
analyze this data to better understand where, how and why downtime
might be occurring—at a fraction of the cost.
An example would be a sensor or button with Bluetooth or Wi-Fi
capability set on a production line to track product (count) or even
movement (if the machine is in operation). This can be expanded to
additional sensors at various points in the process to provide more detail
about where the machine failed and at what frequency, all without human
hands ever touching the data. Many companies use this data collection as
the first step in understanding their issues, or to justify capital investment
or modernization efforts.
 Big Data. Big Data would be a natural progression beyond IIoT because
it uses the data captured from IIoT devices and other systems to identify
events, diagnose root cause, and in some cases even predict these
events. IBM’s Watson Elevator Repairman TV commercial is a great
example of the power of Big Data. Watson reviews historical and real-
time data to predict that Elevator #4 will fail in two days and proactively
calls a repairman.
 Cybersecurity. During Industry 1.0, 2.0 and 3.0, most companies were
concerned about physical security: door locks, security guards, asset tags,
etc. Industry 4.0 considers the security of data and intellectual property
over physical assets. Connecting IIoT devices and existing automated
equipment to any type of network creates vulnerability and increases the
risk associated with a data breach or malicious attack.
Many cyber criminals recognize that it’s easier to penetrate operational
technology (OT) than information technology (IT). Industrial controllers
and OT networks don’t receive the same operating system or application
updates that contain many security fixes included in IT updates. Why is
that?
OT systems are often mission-critical and downtime comes at a premium.
Performing an update in an IT office environment can be done after hours
or during shutdown (can’t we all relate to “please do not shut down,
updates in progress” as we’re trying to power down and go home for the
night?). It’s quite difficult to take down a smelting process or a 365/24/7
manufacturing operation. Having a proper OT strategy, including
cybersecurity, can improve redundancy and reliability, and reduce the risk
of data breach or malicious intent/sabotage.

Something else to consider: While not technically a trend, documentation


becomes even more critical as your organization goes digital. We are often
called into action after a key internal client resource suddenly leaves, taking
critical tribal knowledge and system design with them. These departures bring
to surface the lack of documentation or understanding of key processes and
procedures. Examples include network architecture (what kind/how many
devices are on our network, and why?), information flow (alarms, maintenance
requests, etc.) and programming/logic (if a machine crashes, who can start from
scratch or troubleshoot to bring it back online?). Conducting a formal study into
every aspect of your operation will determine information flow, process
parameters and key points of risk/failure. Documenting these processes will
reduce risk, improve uptime and drive quality.

Companies revolutionizing Operations Management


using Industry 4.0 Include:
 Bosch Automotive is using big data analytics and IIoT to drive its digital
transformation at one of its plants in Wuxi, China. The company has embedded sensors
into its’ factory’s machines which are used to collect data about their conditions and
production cycles. Collected data goes through advanced analytics tools in real time,
which provides manufacturers with important information such as
when bottlenecks have been identified. This technology also allows Bosch to
perform predictive maintenance and keep machinery running for longer. Overall, Bosch
has increased its output by 10% since implementing Industry 4.0 into their
manufacturing operations.
 General Electric implemented the use of augmented reality glasses at its jet
engine manufacturing facility in Cincinnati. These smart wearables have boosted the
productivity of workers at the plant by 11%, according to the company. Instead of
stopping production and reading over manuals, workers have access to digitised
instructions, process metrics and objects information in their field of view as they work.

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