What is Industry 4.0 (Industrial 4.0)?

Industrial IoT (Internet of objects) can be thought of as a comprehensive change that fundamentally restructured the industry, even the next industrial revolution is said to be. This revolution is often known as the previous three industrial revolutions, mechanization (steam engines in the 1800s), mass production (electrical production in the early 1900s) and automation (production managed by computers in the late 1900s) Follow. As the fourth Industrial Revolution (Endüstri 4.0), it brings an approach to hardware and software that monitors, analyzes and manages manufacturing processes through the Internet or other network technologies.

Industry 4.0 is a term adopted by the coalition of universities, corporations, labour unions and government bodies in Germany. This "Industry 4.0" initiative represents the future vision of the country's production, not only in Germany, but also worldwide. The purpose of this joint venture is to keep the country in a leading position as a developer of the "smart factory" technology. This initiative covers a detailed conceptual framework, a clear strategy with specific objectives and milestones, and large financing from private and public sources. This is a public and private policy model that comes together to encourage advanced manufacturing. Bernd Heuchemer, vice president of Siemens Marketing in Germany, said that industry 4.0 's goal is to "help create a new product by combining the characteristics of the physical, virtual, IT, and cyber system world, Actively maintaining the shaping of the

We will use Industry 4.0 as a broader and more general reference for future-intensive changes. It is good to say that industrial IoT and Industry 4.0 are the main cause of the outcome relationship. So the industrial IoT will form the basis of the fourth industrial Revolution and lead to the fourth industrial Revolution. But as a practical matter, this revolutionary revolution will emerge in an evolutionary way. Companies will perform step by step, gradually. The first step is to gain an understanding of what it contains.

Basic standards are important

The ability to connect production equipment to a WEB-based network and gain significant value from these links is more practical and attractive than ever. Although we are in the early stages of this development, there are many studies. For example, well-developed standards such as MTConnect ensure the connection of various production equipment in a typical manufacturing area.  MTConnect offers vocabulary and a specific group of words in a common language, which can be interpreted by software applications. Likewise, this standard is based on standard Internet technology (HTTP, TCP/IP, XML and Ethernet), which are naturally network friendly. MTConnect is also important because it provides key features that are critical to industrial IoT-compliant systems. These systems should include open software architecture, open protocols, and open data models. Otherwise, proprietary elements will interfere with the users and developers of applications running in the industrial IoT.

While MTConnect facilitates the connection of manufacturing equipment to a data acquisition network, standards such as OPC-UA provide interoperability for factory-wide data communication. OPC-UA means "object linking and embedding for unified architectural Process Control". However, it can be explained as a set of open and non-proprietary features that enable automation systems to be compatible with each other.

OPC-UA provides a solution for the problem of "Automation islands" in a large factory. Because factories often have various automated production processes, these systems must be able to communicate with a higher level factory-wide control system. OPC-UA provides the necessary architecture to establish bridges to the data line that connects various automated systems to the rest of the factory. Because this data line can connect to the Internet, it is one of the connections that make up the industrial IoT collectively.

Better, faster and more onsite decision making

Manufacturers implementing industrial Iot solutions will be able to make better decisions. When the devices are connected together, the data they produce flows into software applications that generate information that people can use to make timely and effective choices. By better understanding the results of these decisions, decision makers can achieve strategic objectives or compare performance. Decisions will be based on knowledge and wisdom rather than theory or assumption. Better decisions mean less mistakes and less wasted.

In such a smart factory, administrators will be able to determine that every element of a manufacturing system operates at an optimum level. For example, the parameters such as cutting speeds and feeds, operator experience, cutting tool manufacturer, machine manufacturer and end users will be able to apply the most effective settings according to their demands. Real-time updates to these settings will be automatically applied immediately to maximize efficiency, minimise energy consumption and improve security. Libraries and tool options for programmers will be updated accordingly.

Industrial Iot/Industry 4.0 should be assessed in terms of decisions influenced by each step in the application. Each step should create a basis to make better decisions, prioritize and make them economically realistic.

Human strengthening is essential

Perhaps the most positive and daring aspect of industrial ıot and Industry 4.0 is that the individual will continue to play an active and effective role in manufacturing. Contrary to belief, the importance and effect of this role will increase. Labour, training and development are important because the duties and responsibilities of almost every profession in the manufacturing sector will be affected. Everyone's going to change, because the workflow will change.

Although the industrial IoT is built on software that is used to analyse and manage data for devices and sensors in the production area, the most important sources and consumers of data in a production system are human beings. Keeping people in the data-information-decision-action cycle is of great importance. Employees such as operators, programmers, maintenance engineers, production inspectors and front office operating officers will always work with these systems.

Cyber security is an important issue

According to security experts, cyber threats to industrial IoT are real, global and growing. Threats include trade secrets, intellectual property theft, hostile changes in data, and disruptions or disruption of process control. Manufacturing plants should consider protecting their data, systems and networks at every step to become part of the industrial IoT. Connecting machines to a network or cloud-based application often reveals a number of vulnerabilities that have been ignored. For example, network connections established to a CNC may require a firewall to prevent unauthorized access while allowing for outward communication. Machine data is particularly sensitive because it contains critical information about product design. For example, the CNC tool path and inspection routines for measuring probes represent the dimensions and characteristics of the intended components and thus are an attractive target of hackers.

We advise manufacturing companies to work with solution partners to provide the necessary protection to minimize these threats when creating an intelligent and connected factory.

Next-generation sensors and devices

Sensors detect and measure the physical characteristics or conditions of a device. On/off states, amperage drawing, temperature, pressure, vibration levels and the amount of consumables are examples of "symptoms" that sensors can detect. "Smart sensors" also fulfills other functions. They can convert Analog readings to a digital format; You can process or analyse this data (and even be programmed to perform calculations and react); And you can transmit this data or allow it to be collected over a network for use in a software application.

The location and function of the sensor communication may vary. In some installations it is best to have the sensor "think by itself". In some cases, it will be a "group thoughtful" approach in which sensors and a centralized Data analyzer work together. A mixture of these two could be considered.

Sensors provide information about significant changes. Priority sensors are put in place where they can automatically detect changes affecting the component life cycle. This information will offer warnings about upcoming failures and make unexpected downtime a very rare event. Sensors are the key to detection, intervention and prevention.


With the proliferation of low-cost accurate and interconnected sensors, automated factories will become increasingly efficient. Assembly lines will soon apply to the Iot to diagnose and repair themselves. When tools such as cutters, inserts and drill bits are overcome, the equipment will not only change the team itself, but also connect to its supplier over the network to order new materials.

Tomorrow the machines themselves will definitely communicate through the IoT to order spare parts with their component suppliers.

  • That means less time to waste.
  • It means better asset utilization.
  • Lowers total cost of ownership.
  • Provides a more focused and efficient workforce.
  • Creates more accurate and enforceable performance metrics.
  • It provides more focused expendites.
  • Enables proactive parts replacement and repairs.
  • And ultimately, if it is planned correctly, it provides a better outcome and profitability.

The factories benefiting from IoT, machine learning, robotics and advanced analysis will make even more breathtaking gains in efficiency and output.

An example of such a study is the fact that the IoT and Analytics groups of the U.N. have established the oil producer Santos to build the Iode system, which provides the annual 7.6 million US dollar bill.

As automated machines and smart manufacturing facilities continue to evolve, this revolution will have a greater impact on society. In addition to facilitation of life, it will certainly provide economic benefits. It would be wise to focus carefully on the upcoming Iot and Industrial 4.0 revolution of our eyes.

Volsoft aklıllı üretim sistemi