Unit No: 1

Introduction to Digital
Manufacturing and Sustainability

Dr. Ganesh B. Narkhede

Asst. Professor (Mechanical)
VIIT, Pune

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)
(NBA and NAAC accredited, ISO 9001:2015 certified)
Points to be discussed…
Theme: "Work Smarter, Not Harder: Harnessing Industry 4.0 Advancements."

Syllabus of first unit

What is Industry 4.0 (I4.0) and its importance.

Important I4.0 technologies and their applications, case studies based on these technologies

Triple-bottom-line sustainability: Economic, social, and environmental dimensions,

Interconnection between Industry 4.0 and sustainability goals

Industrial revolutions Key technologies
Industry 1.0 (Late 18th century):
Key Technologies: Steam engine,
mechanization, water power.

Industry 2.0 (Late 19th century):

Key Technologies: Electricity,
internal combustion engine,
assembly line.

Industry 3.0 (Mid-20th century):

Key Technologies: Electronics,
computers, automation.

Industry 4.0 (21st century):

Key Technologies: Internet of
Things (IoT), artificial intelligence
(AI), robotics, big data.
What is Industry 4.0?
• The pursuit of advanced technology has consistently been the driving force behind global
developments and the manufacturing sector has always been at the heart of such developments,
eager to experiment with new concepts and adopt next-generation technologies
• These developments are what caused the journey of industrial revolutions from Industry 1.0 to
Industry 4.0 (I4.0).
• I4.0 refers to the integration of digital technologies, automation, and data exchange in the
manufacturing sector.
• It represents a significant shift in how industries operate and is characterized by the use of
technologies such as IoT, AI, BDA, CPS, Modeling and Simulation, Robotics and Automation, and 3D
printing.
Why Industry 4.0?
• Increased Efficiency and Productivity: I4.0 technologies allows for enhanced automation, real-time
data analysis, and optimized processes.
• Data-Driven Decision-Making: I4.0 emphasizes the use of data analytics for informed decision-
making. The integration of digital technologies provides valuable insights that can be leveraged to
improve operational strategies and outcomes.
• Improved Flexibility and Customization: Smart manufacturing processes enable greater flexibility
and customization in production. Companies can quickly adapt to changing market demands and
deliver more personalized products to consumers.
• Predictive Maintenance: Real-time data analysis minimizes equipment downtime by identifying and
addressing potential issues before they cause failures.
  Mass Customization

Why
Industry 4.0?

Output: Increased flexibility in production

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  Faster Production

Why
Industry 4.0?
Why Industry
4.0?

Output: Data-driven supply chains Virtual modeling of manufacturing process

Digital designs
  Better Quality

Top 100 European

Why manufacturers could save an
Industry 4.0? estimated €160 billion if they
could eliminate all defects.
Why Industry
4.0? Siemens Smart factory

Output: Number of defects per million units

600

500

400

300

200

100

0
1989 2015
  Improved Decision

Why
Industry 4.0?
Why Industry
4.0?

Output: With access to factory and cross-market data, decision makers can
predict future demands, respond quickly to customer demands.
 Industry 4.0 factory could result in decrease of

What can be (Thomas Bauernhansl, et. al. 2016):

 Production costs by 10-30%,

achieved from  Logistic costs by 12-18%,
Industry 4.0
Why Industry  Quality management costs by 15-20%.
implementation
4.0?  Advantages and reasons for adoption of Industry 4.0

 A shorter time-to-market for the new products,

 Enabling a mass customization without significantly increasing

overall production costs,

 More flexibility to respond to custom demands,

 More efficient use of available resources.

Most researched Industry 4.0 technologies in quality research papers
Industry 4.0 technologies and their applications in manufacturing
Internet of Things (IoT)

Smart Connected Devices Data Analysis Robust Network Infrastructure

Sensors and devices Advanced analytics for Highly reliable

enables real-time data predictive maintenance communication networks
collection and continuous and process optimization. for seamless connectivity.
monitoring
Artificial Intelligence & Machine Learning (AIML)

Predictive Analytics Autonomous Systems Personalized Customer Experiences

Advanced algorithms Self-learning systems optimizing Customized recommendations
for forecasting and risk operational processes and and tailored experiences based on
management. decision-making. user behavior.
Big Data Analytics (BDA)

Data Collection Analytical Insights Real-time Monitoring

Collects and processes Extracting valuable insights and Constant monitoring of operations
large data sets from patterns for informed decision- for proactive adjustments and
various sources. making. optimizations.
 Industrial Robots

Automation Collaborative Robots Customization

Performing repetitive Working alongside Highly adaptable to
tasks with precision and humans, enhancing different manufacturing
efficiency. safety and productivity. and assembly processes.
 3D Printing

Rapid Prototyping Supply Chain Optimization

Quickly fabricates prototypes for concept On-demand production, reducing
validation and design iterations. inventory and transportation costs.
Augmented and Virtual Reality (AR & VR)

Training & Simulation Remote Assistance Design Visualization

Immersive training Real-time guidance and Visualizing and
experiences for complex support for field technicians optimizing product
tasks and scenarios. technicians and designs in a virtual
maintenance personnel. environment.
Applications of Industry 4.0 Technologies in Manufacturing

1 Smart Factories
Incorporating IoT, AI, and automation  smart factories
optimum use of available recourses higher revenue.

2 Supply Chain Management

Digital technologies enable end-to-end visibility 
inventory optimization  efficient supply chains.

3 Product Customization
Manufacturers can meet the growing demand for
personalized products.
Applications of I4.0 technologies in other sectors
Triple Bottom Line Sustainability?
• Triple Bottom Line (TBL) sustainability is a framework that considers three key dimensions:
economic, social, and environmental, when evaluating an organization's performance and impact.
• The TBL concept was introduced by John Elkington in 1994 and aims to go beyond traditional
measures of success, such as financial profit, by taking into account broader and more
comprehensive factors.
• The three components of the Triple Bottom Line are:
 Economic (Profit)
 Social (People)
 Environmental (Planet)
1. Economic aspect of TBL
The economic aspect of the Triple Bottom Line (TBL) sustainability framework focuses on the financial
performance and viability of an organization. This dimension considers the economic impact of
business activities, aiming to ensure profitability and long-term financial sustainability. Here are key
points related to the economic aspect of TBL:
1. Profitability: The economic bottom line emphasizes the importance of generating profits and
financial returns for stakeholders. This involves traditional financial metrics such as revenue, profit
margins, return on investment (ROI), and overall financial stability.
2. Cost Efficiency: Organizations committed to TBL sustainability seek to optimize resource use and
minimize waste. Efficient use of resources not only contributes to cost savings but also aligns with
environmental sustainability goals.
3. Investment and Financing: TBL encourages businesses to consider responsible and ethical
investment practices. This involves evaluating the social and environmental impact of investments,
as well as ensuring that financing activities align with sustainable principles.
4. Long-Term Financial Planning: TBL encourages a focus on long-term financial planning rather than
short-term gains. This involves considering the potential risks and opportunities associated with
social and environmental factors that may impact the financial performance of the organization in
the future.
Continue…
5. Supply Chain Management: Economic sustainability is linked to supply chain practices.
Organizations are encouraged to assess the economic implications of their supply chain decisions,
considering factors such as fair labor practices, ethical sourcing, and the overall economic impact on
local communities.

6. Innovation and Market Opportunities: Embracing sustainability can lead to new market
opportunities and innovations. Economic sustainability involves identifying and capitalizing on these
opportunities to create value for the organization while contributing positively to society and the
environment.

7. Job Creation and Economic Development: TBL encourages businesses to consider their role in job
creation and economic development within the communities they operate. This involves fostering fair
labor practices, promoting diversity and inclusion, and contributing to local economic growth.
2. Social aspect of TBL
The social aspect of the Triple Bottom Line (TBL) sustainability framework focuses on the impact of an
organization's activities on people, both within and outside the organization. This dimension goes
beyond financial considerations and emphasizes the importance of social responsibility. Here are key
points related to the social aspect of TBL:
1.Employee Well-being: TBL encourages organizations to prioritize the well-being of their employees.
This involves providing a safe and healthy work environment, fair wages, benefits, and opportunities
for professional development. Employee satisfaction and engagement are crucial indicators of social
sustainability.
2.Diversity and Inclusion: Social sustainability encompasses promoting diversity and inclusion within
the workplace. Organizations are encouraged to create a work environment that respects and values
individuals from diverse backgrounds, fostering an inclusive culture that celebrates differences.
3.Community Engagement: TBL emphasizes the role of businesses in contributing to the well-being of
the communities in which they operate. This involves active engagement with local communities,
supporting local initiatives, and addressing the social needs of those communities.
4.Ethical Business Practices: Social responsibility includes maintaining ethical business practices. This
involves ensuring transparency, honesty, and integrity in all dealings, both internal and external.
Ethical behavior builds trust among stakeholders and contributes to the overall social sustainability of
the organization.
Continue…
5. Human Rights: Organizations are expected to respect and uphold human rights in all aspects of their
operations. This includes ensuring that business activities do not contribute to human rights abuses,
both within the organization and across its supply chain.
6. Labor Practices: Social sustainability involves fair labor practices, including adherence to labor laws,
the right to organize, and the prevention of exploitative practices. Organizations are encouraged to
establish and maintain responsible labor practices throughout their operations.
7. Health and Safety: Ensuring the health and safety of employees and stakeholders is a fundamental
aspect of social sustainability. This involves implementing measures to prevent workplace accidents,
providing adequate safety training, and promoting a culture of health and well-being.
8. Stakeholder Engagement: TBL advocates for active engagement with various stakeholders, including
customers, suppliers, employees, and local communities. Understanding and responding to the needs
and concerns of stakeholders contribute to the overall social sustainability of the organization.
9. Philanthropy and Social Impact: Organizations are encouraged to contribute positively to society
through philanthropic activities and social impact initiatives. This may involve supporting charitable
causes, environmental conservation efforts, or community development projects.
3. Environmental aspect of TBL
The environmental aspect of the Triple Bottom Line (TBL) sustainability framework focuses on the
impact of an organization's activities on the natural world. This dimension considers the environmental
responsibility of businesses and seeks to minimize their ecological footprint. Here are key points
related to the environmental aspect of TBL:
1.Resource Conservation: TBL emphasizes the responsible and sustainable use of natural resources.
Organizations are encouraged to adopt practices that minimize resource consumption, promote
efficiency, and reduce waste generation.
2.Energy Efficiency: Environmental sustainability involves a commitment to energy efficiency and the
reduction of greenhouse gas emissions. Organizations are encouraged to implement energy-efficient
technologies, embrace renewable energy sources, and strive for carbon neutrality.
3.Waste Reduction and Recycling: TBL promotes the reduction of waste and the adoption of recycling
practices. Organizations are encouraged to minimize the generation of non-recyclable waste,
implement recycling programs, and explore innovative solutions for waste management.
4.Biodiversity Preservation: Organizations are urged to consider the impact of their activities on
biodiversity. This involves avoiding practices that harm ecosystems, habitats, and endangered species.
Conservation efforts and responsible land use are crucial components of environmental sustainability.
Continue…
5. Carbon Footprint Reduction: TBL encourages organizations to measure and reduce their carbon
footprint. This includes assessing emissions from operations, transportation, and supply chains, and
implementing strategies to decrease overall carbon emissions.
6. Pollution Prevention: Environmental sustainability involves preventing and minimizing pollution.
Organizations are encouraged to adopt practices that reduce air, water, and soil pollution, as well as
limit the use of harmful chemicals in their processes.
7. Sustainable Supply Chains: TBL considers the environmental impact of supply chain activities.
Organizations are encouraged to work with suppliers who follow environmentally responsible
practices, reducing the overall environmental impact associated with the production and
transportation of goods and services.
8. Water Conservation: Responsible water use is a key component of environmental sustainability.
Organizations are encouraged to implement water conservation measures, manage water usage
efficiently, and consider the impact of their activities on local water resources.
Continue…
9. Environmental Compliance: TBL emphasizes adherence to environmental regulations and
standards. Organizations are expected to comply with laws and regulations related to environmental
protection, and strive to exceed minimum requirements in their environmental stewardship efforts.
10. Sustainable Innovation: Environmental sustainability involves fostering a culture of innovation that
prioritizes sustainable solutions. Organizations are encouraged to invest in research and development
to create products, services, and processes that have minimal environmental impact.
Interconnection of Industry 4.0 and sustainability goals
Industry 4.0 and sustainability goals are interconnected in several ways, as the integration of advanced
technologies within industrial processes can contribute to more sustainable practices. Industry 4.0
refers to the fourth industrial revolution, characterized by the use of smart technologies, data-driven
decision-making, and automation in manufacturing and other industries. Here are key points
highlighting the interconnection between Industry 4.0 and sustainability goals:
1.Resource Efficiency:
 Industry 4.0 Technologies: Technologies such as the Internet of Things (IoT), sensors, and data
analytics enable real-time monitoring and optimization of resource usage in manufacturing
processes.
 Sustainability Impact: By optimizing resource consumption, companies can reduce waste, energy
consumption, and raw material usage, contributing to sustainability goals related to resource
efficiency.
2. Energy Management:
 Industry 4.0 Technologies: Smart grids, energy monitoring systems, and automation help industries
manage energy consumption more efficiently.
 Sustainability Impact: Reduced energy consumption leads to lower greenhouse gas emissions and a
smaller environmental footprint, aligning with sustainability goals focused on energy efficiency and
climate action.
Interconnection of Industry 4.0 and sustainability goals
3. Supply Chain Transparency:
 Industry 4.0 Technologies: Blockchain and IoT provide transparent and traceable supply chain
information, allowing stakeholders to monitor and verify sustainable practices throughout the supply
chain.
 Sustainability Impact: Enhanced supply chain transparency supports sustainability goals by ensuring
ethical sourcing, reducing environmental impact, and promoting fair labor practices.
4. Circular Economy Practices:
 Industry 4.0 Technologies: Advanced manufacturing technologies, like 3D printing, support the principles
of a circular economy by enabling efficient recycling, remanufacturing, and customization of products.
 Sustainability Impact: The adoption of circular economy practices reduces waste and promotes the
efficient use of resources, aligning with sustainability goals related to waste reduction and responsible
consumption.
5. Smart Buildings and Infrastructure:
 Industry 4.0 Technologies: Smart building solutions, powered by IoT and data analytics, enable better
energy management, predictive maintenance, and overall operational efficiency.
 Sustainability Impact: Improved building and infrastructure efficiency contribute to sustainability goals
by reducing energy consumption, enhancing resilience, and minimizing environmental impact.
Interconnection of Industry 4.0 and sustainability goals
6. Life Cycle Assessment:
 Industry 4.0 Technologies: Data analytics and simulation tools facilitate life cycle assessments, allowing
companies to analyze and optimize the environmental impact of products from design to disposal.
 Sustainability Impact: Considering the entire life cycle of products helps identify opportunities for
environmental improvement, supporting sustainability goals related to responsible consumption and
production.
7. Remote Monitoring and Maintenance:
 Industry 4.0 Technologies: Remote monitoring and predictive maintenance technologies reduce the
need for physical inspections, minimizing travel and resource use.
 Sustainability Impact: Remote technologies contribute to sustainability goals by reducing the carbon
footprint associated with travel and optimizing maintenance processes.
8. Digital Twin Technology:
 Industry 4.0 Technologies: Digital twins, virtual representations of physical objects or systems, enable
better understanding and optimization of industrial processes.
 Sustainability Impact: By simulating and optimizing processes, digital twin technology contributes to
sustainability goals by minimizing errors, improving efficiency, and reducing resource waste.
Case studies of I4.0 technologies
Siemens’ digital factory, Amberg, Germany Schneider electric’s smart factory, Indonesia.
Automation, robotics, and digitalization. Through real-time Advanced robotics, IoT, and data analytics to optimize energy
data monitoring and analysis, Siemens optimized energy usage, consumption, reduce waste, and enhance productivity.
reduced waste, and improved production processes. The digital Through real-time energy monitoring and predictive
factory achieved a 15% reduction in energy consumption and a maintenance, the factory achieved a 10% reduction in energy
50% decrease in CO2 emissions. consumption and improved overall equipment effectiveness.

Interface Inc, USA, modular flooring company BMW, A leading automobile manufacturer
•69% reduction in carbon footprint, Utilized 3D printing to produce customized parts with reduced
•96% reduction in Greenhouse Gas emissions globally,
material waste and enhanced design flexibility. By adopting
• 89% renewable energy use across its factories globally,
• 99% renewable energy use in U.S. and European this approach, BMW achieved weight reduction in their
manufacturing sites, vehicles, leading to improved fuel efficiency and reduced
•89% water use reduction per unit of production in factories carbon emissions.
globally
 First case example from IndiTech Valves Pvt Ltd
Customer inspection from remote locations using Smart Helmet

• These days, customers ask for live

inspections from their locations.
• Smart helmet: VIIT (Mrs. Dipti Pandit)
• Customers need not to come to supplier’s
end, they can ensure the quality from
their own location with this smart helmet
Third case example from IndiTech Valves Pvt Ltd
Live inspection from remote locations
Second case example from IndiTech Valves Pvt Ltd
Speed, feed, and DOC optimization using BDA, IoT
Third case example from IndiTech Valves Pvt Ltd
Welding using robotic arm at existing rotating welding table
Reasons for low sustainability of I4.0 technologies
Reasons for low sustainability of I4.0 technologies
Organizational Barriers Labor/HR Barriers

Non-availability of digital strategy. Lack of training for workers.

Lack of senior management support system. Less educated workforce.
Risky investment on technologies. Low perceptions for digital revolution.
Higher investment on employees' training. Lack of creative thinking.
High cost for recruitment of skilled workforce.
Non-availability of data-based service system.
Technological Barriers Other Barriers
High cost of technology. Unavailability of government policies.
Unavailability of data security system Lack of supports from government.
Unavailability of IT infrastructure. Fluctuation in production schedules
Unavailability of service centers. Lack of communication between management and workers.
Lack of consultants and trainers required in the field.
Incompatibility of digital technologies with the company bonus, rewards or
incentives systems.
 Roadmap for
Implementation
of Industry 4.0
technologies
 Any Question?
BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)
 Email ID: ganesh.Narkhede@viit.ac.in
Mob: +91 9767895083

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)