Obviously there is a lot of marketing in this story, but there is also something that is true: the technology is allowing to go one step further in the production processes, and in general in the way we live. And the step is not exactly small.
Throughout the history of the industry, one can speak of different moments in which a new technological advance It was a big change, revolution. First was the invention of the steam machine at the end of the XNUMXth century, which allowed the introduction of mechanical equipment powered by steam power; second, during the second half of the nineteenth century, the use of electricity and chain production they supposed a great increase in the productive capacity; later, well into the XNUMXth century, progress in electronics e computers made it possible to automate a large part of the production process. And now we are living what has been called the Fourth Industrial Revolution, or as you prefer, Industry 4.0.
But what does this consist of? fourth revolution? Basically, in bringing to the industry what we are already experiencing in other areas: everything has to be connected, making it possible to access any data from anywhere, with any device. Industry 4.0 means having the layers of the production processes of a factory (OT) connected with the administrative layers (IT), being much easier and faster have the information necessary for analysis and decision making. PLCs with web servers, smart sensors, RFID systems for traceability... all of this is already being used in many factories, but there is much more to come.
Eg augmented reality will allow the operator to view interesting information on the different machines just by taking a walk through the factory with a tablets as a guide.
The capture of all the data generated by the processes will contribute to the creation of a large database (big data) that allows the creation of descriptive and predictive models to be exploited with the aim of achieving the maximum efficiency in the management of available resources.
The use of cloud o cloud will make not only all this information, but also the applications to exploit it, available from any place.
La Print 3D allows the manufacture of to prototypes quickly and economically, as well as the customization in the manufacture of certain parts.
A new generation of robots, called robots collaborative o cobots, are beginning to arrive to work side by side with humans without the latter suffering the slightest risk.
And, of course, sensors and actuators capable of self-manage themselves, give information about diagnosis and provide accessible data remotely via the local network and the internet, as part of the call industrial internet of things (industrial internet of things o IIoT).
It is important to say that the fact of having all connected and available from abroad gives special relevance to the issue of ciberseguridad. The main manufacturers in the sector have already put different components on the market to avoid not only the appearance of intruders, but also that certain operations involuntary of the legitimate user of the system can cause serious problems.
The interconnection of all the machines and processes in the smart factory will make it possible to approach self-management. In short, the factory based on Industry 4.0 will increase its efficiency, will win in flexibility and will be able to offer products training to its customers, with a Delivery time y costes reduced. And it will be important not to be left behind in this race…
I agree that automation in industrial processes is very important, but this started several years ago in Chile, I was Superintendent of Instrumentation and Automatic Control, at the Arauco Pulp Mill, I had to participate in the decision in the definition of the first Distributed Control System (DCS), I was sent to see the installations of some systems installed in the USA, there were not many (year 1984) I visited the Taylor Plant, Fisher Control in Austin (Texas) and in Arizona Phoenix the The largest Honeywell control system plant that had the TDC 2000 in those years, then they released the TDC 3000, and with all the information obtained, Arauco Plant in Plant No. 1, the MOPA project was carried out, in that Project it only had 5 Engineers As my support, we carried out a total control project with independent control loops, as suggested by some engineers of the external project, everything was left with DCS control with the Taylor MOD-300 V7 system. 6.3, everything worked from the beginning without any delay, it was a great job with my Engineers and Technician subordinates, the production people were well trained, a lot fell by the wayside, it was a very strong change especially for the operators, we had a lot success, in 1990 studies began to install Plant No. 2, which had a production twice that of plant No. 1 of 1500 tons/day, plant No. 1 is 750 tons/day, we also had a great challenge and Of course, the Canadian and Chilean project engineers estimated a different DCS system from the one used in plant No. 1. I had to make the decision against them that they went for a DCS Bailey Infi 90, but I insisted that if we already had experience in the Taylor system both the Instrumentation and Operations people consider it unwise to change the system, and what I decided was a Taylor Mo300 installed but with a more modern version MOD-300 version 14.0, a lot of work was done but the engineers I had as Subordinates were n 14 everything worked without any problem, I am proud to have been at the head of both projects, my Subordinates are very good Electronic Engineers from the University of Concepción, and many of them are Managing another plant in Chile and in the USA and Canada, I must say that the experience I acquired in the projects and in the operation of all the control systems, from the measurement to the final element of control, passed through our decision, there was very little external engineering, all that was 23 years, I They are used to teach classes in Universities and Professional Institutes, with a lot of support from the field, in addition to dictating a diploma that Inacap delivered, in automatic control, now only classes in Universities and Technical Seminars via Sence, I am calm since I contribute, experience and Subalterns came out of very good quality, greetings
Dear William.
Thanks a lot for sharing your experience. It is important that your students take advantage of it now so that they become good professionals.
A greeting.
Interesting point of view. Not long ago we were in the 3.0 era and we have already taken a level jump. Technology doesn't wait and if you don't adapt you go ahead to the left and right
Dear David and readers,
Industry 4.0, in my humble opinion, is a term coined as a claim for systems that already existed long ago, but with the aim of refreshing themselves for the market with new interfaces and communications, generating apparently new products.
I have asked a good number of professionals about this term and each one gave me a different definition, perhaps none of them has a really clear idea of this, but this song "sounds familiar" to them or each one understands this in their own way... it reminds me to that of the Meigas... nobody saw them but...
In any case, good for freedom in technology, but it gives the impression that either you have this term in your Power Points or you are out of “cool”….
On the other hand, in the company where I work we are already in Industry 5.0, that is… that the systems notify you before they break down and stop production, that the solution to everyday problems comes to us and we do not have to go looking for it… and know how your machinery or plant is in real time…this is simply called “trust”, it allows you to sleep better and use your capacity in continuous improvement and not in the survival of your processes.
It's not about having control, we already have it, it's about not being aware of what task Murphy will have prepared for me today, ... This is ... demonstrating how it works in your hand ... therefore I think this is 5.0 because already it's real...of course this doesn't appear with a gesture like Iron Man's computers but you have to implement it step by step letting experienced professionals advise you on your projects...you already know that everything fits in a presentation...even dreams 🙂 , you have to know how to distinguish between dreams and realities, and it is not easy nowadays.
We have lost our capacity for wonder…so much so, that we have to develop not only impressive systems, but describe them in the same way so that they do not go unnoticed…double work therefore…
Fortunately, this work gives results and I find professionals who know how to listen and are prepared to implement and offer something more to their clients.
A hug to all, oh! and Happy Holidays!!!