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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

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OUTLINE
What is Industry 4.0?
Why Industry 4.0?
Challenges

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WHAT IS INDUSTRY 4.0?

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WHAT IS INDUSTRY 4.0?
Source: Lev Grossman, “2045: The Year Man Becomes Immortal,” TIME Magazine, February, 2011.
• Human Scientific Progress

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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.

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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

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WHAT IS INDUSTRY 4.0?

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WHAT IS INDUSTRY 4.0?
Mechanization
Electrification
Automation

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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

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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.

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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

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• 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

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WHY INDUSTRY 4.0?

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WHY INDUSTRY 4.0?
Better Quality
Increased
Productivity
Sharing
Economy
Improved
Decision
Making
Mass
Customization
Faster
Production
Industry 4.0

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WHY INDUSTRY 4.0?
Increased flexibility in production and manufacturing on demand
• Mass Customization

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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

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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.

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WHY INDUSTRY 4.0?
• Increased Productivity
Lights out/Dark factories work 24/7

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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]

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WHY INDUSTRY 4.0?
• Sharing Economy

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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

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CHALLENGES

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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

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CHALLENGES
• Big Data

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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

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CHALLENGES
• Social Impact

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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.

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CHALLENGES
• Social Impact
Better in
Dull
Dangerous
Dirt
Dumb
Robots find
applications in
“4D tasks”

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CHALLENGES
• Social Impact

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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

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Thank you for your attention!
Questions?
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