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Industry 4.0 and Smart Factory

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Industry 4.0 and Smart Factory

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The fourth industrial revolution Industry 4.0 represents a new paradigm shift from “centralized” to “decentralized” industry relies on cyber-physical based automation where sensors send data directly to the cloud and services such as monitoring, control and optimization automatically subscribe to necessary data in real-time. In the coming years, these technologies will be seen as a viable alternative to current manufacturing processes. According to a recent report by Markets and Markets, smart factory technology will have global market size of 74.80 Billion USD by 2022. The talk provides a comprehensive introduction to Industry 4.0 and Smart Factory. Technical challenges and social implications of smart factory will be discussed. The applicability of these emerging technologies in developing economies is highlighted in this talk as well.

The fourth industrial revolution Industry 4.0 represents a new paradigm shift from “centralized” to “decentralized” industry relies on cyber-physical based automation where sensors send data directly to the cloud and services such as monitoring, control and optimization automatically subscribe to necessary data in real-time. In the coming years, these technologies will be seen as a viable alternative to current manufacturing processes. According to a recent report by Markets and Markets, smart factory technology will have global market size of 74.80 Billion USD by 2022. The talk provides a comprehensive introduction to Industry 4.0 and Smart Factory. Technical challenges and social implications of smart factory will be discussed. The applicability of these emerging technologies in developing economies is highlighted in this talk as well.

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Industry 4.0 and Smart Factory

  1. 1. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 1/221 Industry 4.0 and Smart Factory Alaa Khamis, PhD, SMIEEE Head of Advanced Development Division at Sypron Solutions http://www.alaakhamis.org/ Maker Faire Cairo 2017 © Dr. Alaa Khamis
  2. 2. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 2/222 2 2017 © Dr. Alaa Khamis OUTLINE What is Industry 4.0? Why Industry 4.0? Challenges
  3. 3. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 3/223 3 2017 © Dr. Alaa Khamis WHAT IS INDUSTRY 4.0?
  4. 4. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 4/224 4 2017 © Dr. Alaa Khamis WHAT IS INDUSTRY 4.0? Source: Lev Grossman, “2045: The Year Man Becomes Immortal,” TIME Magazine, February, 2011. • Human Scientific Progress
  5. 5. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 5/225 5 2017 © Dr. Alaa Khamis WHAT IS INDUSTRY 4.0? Agriculture revolution Industrial revolution Light bulb Moon landing World Wide Web Human Genome Sequenced 8,000years 120 years 90 years 22 years 9years • The accelerating pace of change Source: Lev Grossman, “2045: The Year Man Becomes Immortal,” TIME Magazine, February, 2011.
  6. 6. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 6/226 6 2017 © Dr. Alaa Khamis Time to reach 100 Million customers Telephone 75 Years Web 7 Years Facebook 4 Years Instagram 2 Years Pokemon Go 1 Month WHAT IS INDUSTRY 4.0? • The accelerating pace of change
  7. 7. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 7/227 7 2017 © Dr. Alaa Khamis WHAT IS INDUSTRY 4.0?
  8. 8. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 8/228 8 2017 © Dr. Alaa Khamis WHAT IS INDUSTRY 4.0? Mechanization Electrification Automation
  9. 9. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 9/229 9 2017 © Dr. Alaa Khamis Cost-efficiently Quickly Flexibly WHAT IS INDUSTRY 4.0? Shorter lead time/product life cycle Larger product variance For both large volume and small quantities
  10. 10. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 10/2210 10 2017 © Dr. Alaa Khamis WHAT IS INDUSTRY 4.0? Digitalization Automation Connectivity Analytics Source: B. Roland, "INDUSTRY 4.0: The new industrial revolution How Europe will succeed," Think Act, Tech. Report, 2014.
  11. 11. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 11/2211 11 2017 © Dr. Alaa Khamis WHAT IS INDUSTRY 4.0? Emerging Cyber Physical System-based Automation Classical 5-Layer Automation Architecture ERP MES SCADA PLC Sensors-Actuators Factory Operation Management Level Process Control Level Cell Level Station Level Machine Level
  12. 12. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 12/2212 12 2017 © Dr. Alaa Khamis • Global Market Size Forecast in 2019 (USD Billion) WHAT IS INDUSTRY 4.0? Smart Factory technology will have global market size of 74.80 Billion USD by 2022. [Markets & Markets] 293.57 115 62.98 29.53 15.25 5.3 0 50 100 150 200 250 300 IoT Big data Smart Factory Advanced Analytics Service Robotics Smart Machines
  13. 13. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 13/2213 13 2017 © Dr. Alaa Khamis WHY INDUSTRY 4.0?
  14. 14. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 14/2214 14 2017 © Dr. Alaa Khamis WHY INDUSTRY 4.0? Better Quality Increased Productivity Sharing Economy Improved Decision Making Mass Customization Faster Production Industry 4.0
  15. 15. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 15/2215 15 2017 © Dr. Alaa Khamis WHY INDUSTRY 4.0? Increased flexibility in production and manufacturing on demand • Mass Customization
  16. 16. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 16/2216 16 2017 © Dr. Alaa Khamis WHY INDUSTRY 4.0? Virtual modeling of manufacturing process • Faster Production Digital designs Speed up the manufacturing process : Data-driven supply chains 120% in time needed to deliver orders 70% in time to get products to market
  17. 17. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 17/2217 17 2017 © Dr. Alaa Khamis WHY INDUSTRY 4.0? • Better Quality Siemens Smart factor for custom Programmable Logic Controls (PLCs) 500 12 0 100 200 300 400 500 600 1989 2015 Number of defects per million units 99.99% reliability rate Top 100 European manufacturers could save an estimated €160 billion in the costs of scrapping or reworking defective products if they could eliminate all defects.
  18. 18. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 18/2218 18 2017 © Dr. Alaa Khamis WHY INDUSTRY 4.0? • Increased Productivity Lights out/Dark factories work 24/7
  19. 19. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 19/2219 19 2017 © Dr. Alaa Khamis WHY INDUSTRY 4.0? • Increased Productivity Predictive maintenance avoids machine failures on the factory floor 50% decreased downtime 20% increased production Predictive maintenance will help companies save $630 Billion by 2025 [McKinsey]
  20. 20. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 20/2220 20 2017 © Dr. Alaa Khamis WHY INDUSTRY 4.0? • Sharing Economy
  21. 21. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 21/2221 21 2017 © Dr. Alaa Khamis WHY INDUSTRY 4.0? • Improved Decision Making With access to factory and cross-market data, decision makers can predict, response, and adapt to factory needs and market trends
  22. 22. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 22/2222 22 2017 © Dr. Alaa Khamis CHALLENGES
  23. 23. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 23/2223 23 2017 © Dr. Alaa Khamis CHALLENGES General reluctance to change by stakeholders Lack of adequate skill-sets Unemployment Communication reliability and QoS Cyber security Maturity of machine intelligence Handling big data Technical Challenges Social Impact
  24. 24. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 24/2224 24 2017 © Dr. Alaa Khamis CHALLENGES • Big Data
  25. 25. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 26/2226 26 2017 © Dr. Alaa Khamis CHALLENGES • Big Data RADAR: ~10-100 KB per second SONAR: ~10-100KB per second Camera: ~20-40 MB per second LIDAR: ~10-70 MB per second GPS: ~50 KB per second Autonomous Vehicle 4 TB Per Day
  26. 26. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 27/2227 27 2017 © Dr. Alaa Khamis CHALLENGES • Social Impact
  27. 27. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 28/2228 28 2017 © Dr. Alaa Khamis CHALLENGES • Social Impact A study out of Oxford University in 2014 found that in the near future artificially intelligent technology could take over nearly half of all U.S. jobs. We can expect a wave of structural unemployment to spring from the technology in the medium term.
  28. 28. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 29/2229 29 2017 © Dr. Alaa Khamis CHALLENGES • Social Impact Better in Dull Dangerous Dirt Dumb Robots find applications in “4D tasks”
  29. 29. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 30/2230 30 2017 © Dr. Alaa Khamis CHALLENGES • Social Impact
  30. 30. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 31/2231 31 2017 © Dr. Alaa Khamis CHALLENGES • Social Impact Machine Human Creative Lower initial cost and higher running cost Faster More precise Able to work in harsh environments Higher initial cost and lower running cost
  31. 31. MUSES_SECRET: ORF-RE Project - © PAMI Research Group – University of Waterloo 32/2232 32 2017 © Dr. Alaa Khamis Thank you for your attention! Questions? Maker Faire Cairo 2017 © Dr. Alaa KhamisView publication statsView publication stats

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