Industry 4.

0
Training: Industry 4.0
Date: 09.08.2023
Location: Metso Alwar
Trainer Name: Virender Singh
Trainer Email: virender.singh@cii.in

Contents
Background and overview of Industry 4.0 2
What is Industry 4.0 ? Different industrial revolution 2
Difference between Digitisation, Digitalisation & Industry 4.0 2
What is IOT / IIOT ? 2
Six principles of Industry 4.0 2
How to leverage the principles (Cyber Physical systems, Interoperability, Virtualization, Decentralization,
Real-Time Capability, Service orientation and Modularity) to identify & implement relevant technology
pillars 2
Briefing and application – Nine Technological Pillars of Industry 4.0 2
Application and use case studies of I 4.0 technological components in different application 2
AR / VR / MR / Digital Twins 2
Briefing on AI (Artificial Intelligence) / ML (Machine Learning) / DL (Deep Learning) 2
Preventive Maintenance (PM) vs Condition Based Maintenance (CBM) 2
How to leverage VR / AR in HR Induction Trainings or TPM – Jishu-Hozen (JH) or Improving
maintenance KPIs 2
 Industry 4.0

This workshop introduces participants to the basic terminology, concept, and goals of Industry
4.0 (DRA – Digitalisation, Robotics and Automation), the different pillars of Industry 4.0,
design, and implementation. Use case studies from industry will be used for easy understanding
for participants.

Objective of the “Introduction to Industry 4.0 / DRA” workshop is to create Industry 4.0
awareness supported by use cases across the Indian industries, covering all manufacturing
sectors. Know-how of Industry 4.0 & its benefits to the industry to enhance business excellence.
What is Industry 4.0, or the Industrial Internet of Things (IIoT)?

How the large-scale companies and Micro, Small, Medium Scale (MSME) companies,
effectively initiate this complex transformation to DRA / Industry 4.0? Industry 4.0 workshop
would support managers in leading these initiatives.

Background and overview of Industry 4.0

Industry 4.0 refers to the fourth industrial revolution, characterized by the integration of digital
technologies, advanced data analytics, and the Internet of Things (IoT) into various aspects of
industrial processes and manufacturing. This term was coined in Germany in 2011 as part of a
government initiative to promote the computerization of manufacturing, and it has since gained
international recognition.

Background: The progression of industrial revolutions provides context for Industry 4.0:
 Industry 4.0
1. First Industrial Revolution: This period saw the shift from agrarian economies to
mechanized industries with the advent of steam engines and mechanized textile
production in the late 18th and early 19th centuries.
2. Second Industrial Revolution: Occurred in the late 19th and early 20th centuries,
marked by mass production facilitated by electrical power, the assembly line, and
increased mechanization.
3. Third Industrial Revolution (Digital Revolution): This took place in the late 20th
century, marked by the widespread adoption of computers and digital technologies,
enabling automation and computerization of various processes.

Overview of Industry 4.0: Industry 4.0 builds upon the foundation of the third industrial
revolution, introducing a new level of interconnectedness and intelligence to manufacturing and
industry. Key characteristics and technologies associated with Industry 4.0 include:

1. Interconnectivity: Industrial processes, machines, and devices are connected through the
Internet of Things (IoT), allowing them to communicate and share data in real-time. This
enables more efficient monitoring and control of production processes.
2. Advanced Data Analytics: The massive amount of data generated by interconnected
devices is collected and analyzed using sophisticated algorithms and analytics tools. This
enables companies to gain insights into their operations, optimize processes, and make
data-driven decisions.
3. Smart Manufacturing: Factories and production lines become more flexible and
adaptive. Machines can be reconfigured and reprogrammed remotely to accommodate
changes in production needs.
4. Cyber-Physical Systems: These are the integration of physical processes with digital
technologies. Sensors and actuators embedded in physical systems interact with digital
components to create a seamless connection between the physical and virtual worlds.
5. Cloud Computing: Cloud-based platforms enable companies to store and process large
amounts of data without requiring extensive local infrastructure. This facilitates
scalability and accessibility.
6. Autonomous Systems: Machines and processes become increasingly autonomous and
capable of self-optimization. This includes technologies like robotics, which can perform
tasks with minimal human intervention.
7. Additive Manufacturing (3D Printing): This technology allows for the creation of
complex, customized products layer by layer, disrupting traditional manufacturing
processes.
8. Augmented Reality (AR) and Virtual Reality (VR): These technologies enhance
training, maintenance, and design processes by overlaying digital information onto the
physical environment.
9. Cybersecurity: With increased connectivity comes the need for robust cybersecurity
measures to protect sensitive data and prevent unauthorized access to critical systems.
10. Global Supply Chain Integration: Industry 4.0 can lead to more integrated and
responsive supply chains, enabling just-in-time production and reducing waste.

Overall, Industry 4.0 represents a transformative shift in how industries operate, blurring the
lines between physical and digital realms and enabling new levels of efficiency, customization,
and innovation.
 Industry 4.0
What is Industry 4.0? Different industrial revolution

Industry 4.0, also known as the fourth industrial revolution, refers to the integration of digital
technologies, advanced data analytics, and the Internet of Things (IoT) into various aspects of
industrial processes and manufacturing. It represents a paradigm shift in the way industries
operate, bringing together physical systems and digital technologies to create more efficient,
connected, and intelligent production processes.

Key characteristics of Industry 4.0 include:

1. Interconnectivity: Industrial devices, machines, and processes are connected through the
Internet of Things (IoT) and other communication technologies. This enables real-time
data exchange and communication between different parts of the production process.
2. Data Analytics: The massive amount of data generated by interconnected devices is
collected and analyzed using advanced algorithms and analytics tools. This data-driven
approach allows companies to gain insights into their operations, optimize processes, and
make informed decisions.
3. Smart Manufacturing: Factories and production lines become more flexible and
adaptable. Machines can be remotely reconfigured and reprogrammed to respond to
changing production needs and requirements.
4. Cyber-Physical Systems: These systems integrate physical processes with digital
technologies. Sensors and actuators embedded in physical systems interact with digital
components, creating a seamless connection between the physical and virtual worlds.
5. Autonomous Systems: Industry 4.0 introduces greater autonomy to manufacturing
processes. Machines and processes can operate with minimal human intervention,
performing tasks with a high degree of automation.
6. Additive Manufacturing (3D Printing): This technology allows for the creation of
complex, customized products layer by layer. It disrupts traditional manufacturing
processes and enables more agile and efficient production.
7. Augmented Reality (AR) and Virtual Reality (VR): AR and VR technologies enhance
training, maintenance, and design processes by overlaying digital information onto the
physical environment, improving efficiency and accuracy.
8. Cloud Computing: Cloud-based platforms provide storage and processing capabilities
for the vast amounts of data generated by Industry 4.0 systems. This facilitates scalability
and accessibility of data and software resources.
9. Global Supply Chain Integration: Industry 4.0 can lead to more integrated and
responsive supply chains, allowing for just-in-time production and reducing waste.
10. Cybersecurity: With increased connectivity, robust cybersecurity measures become
crucial to protect sensitive data and prevent unauthorized access to critical systems.

Overall, Industry 4.0 aims to create "smart factories" where production processes are highly
efficient, flexible, and responsive to market demands. It revolutionizes how products are
designed, manufactured, and delivered, ushering in a new era of innovation and competitiveness
for industries worldwide.

Certainly! Let's explore the different industrial revolutions and how they lead up to Industry 4.0:

1. First Industrial Revolution (Late 18th - Early 19th Century):

 Industry 4.0
 Characterized by the transition from agrarian and craft-based economies to mechanized and
factory-based production.
 Innovations: Steam engine, mechanized textile production, and mechanized transportation (such
as trains).

2. Second Industrial Revolution (Late 19th - Early 20th Century):

 Marked by the further expansion of mechanization, introduction of mass production techniques,

and increased use of electricity.
 Innovations: Electricity, assembly line, internal combustion engine, telegraph, and telephone.

3. Third Industrial Revolution (Late 20th Century):

 Often referred to as the Digital Revolution, it brought widespread computerization and

automation.
 Innovations: Computers, microprocessors, digital communication, and the internet.

4. Industry 4.0 (Current Era):

 Industry 4.0 is the ongoing fourth industrial revolution, characterized by the fusion of digital
technologies, automation, and data exchange in manufacturing and other industries.
 Innovations: Internet of Things (IoT), advanced data analytics, cloud computing, cyber-physical
systems, augmented reality, additive manufacturing (3D printing), and more.

Industry 4.0 represents a continuation and evolution of the trends set in motion by the previous
industrial revolutions. It builds upon the digital foundation laid by the third industrial revolution
and extends it into a more interconnected, intelligent, and automated realm. The focus of
Industry 4.0 is on enhancing efficiency, flexibility, and innovation in manufacturing and
industrial processes through the integration of cutting-edge technologies.

In summary, Industry 4.0 is the latest phase in the progression of industrial revolutions, marked
by the convergence of physical and digital technologies to create smarter, more efficient, and
more adaptable manufacturing processes.

Difference between Digitization, Digitalization & Industry 4.0

Digitization, Digitalization, and Industry 4.0 are related concepts, but they have distinct
meanings and implications in the context of technological advancements and their impact on
industries. Here's a breakdown of their differences:

1. Digitization:
o Definition: Digitization refers to the process of converting analog information into digital
format. It involves taking physical data or content (such as text, images, or sound) and
transforming it into a digital representation that can be stored, manipulated, and
transmitted electronically.
o Example: Converting paper documents into digital files, or converting analog audio
recordings into digital audio files.

2. Digitalization:
 Industry 4.0
o Definition: Digitalization is the broader process of using digital technologies to transform
business processes, operations, and models to gain efficiencies and create new value. It
involves the integration of digital technologies into various aspects of an organization's
activities, often leading to improved workflows, data-driven decision-making, and
enhanced customer experiences.
o Example: Implementing software systems to manage inventory, using digital platforms
for customer engagement, or transitioning from paper-based workflows to digital
workflows.

3. Industry 4.0:
o Definition: Industry 4.0, also known as the fourth industrial revolution, represents the
integration of digital technologies, advanced data analytics, and the Internet of Things
(IoT) into industrial and manufacturing processes. It's a paradigm shift that combines
physical processes with digital technologies to create "smart" factories and production
systems.
o Example: Implementing sensors on machinery to monitor performance in real-time, using
data analytics to optimize production processes, or creating interconnected production
lines that can communicate and adjust autonomously.

In summary:

 Digitization is the process of converting analog information into digital format.

 Digitalization is the broader transformation of business processes using digital technologies.
 Industry 4.0 is the specific application of digital technologies, data analytics, and IoT to
manufacturing and industrial processes, creating interconnected and intelligent production
systems.

All three concepts are interconnected and often work together as organizations embrace
technological advancements to improve their operations, create new business models, and remain
competitive in the modern landscape.

What is IOT / IIOT?

 Data collected often for personal use and insights.

IIoT (Industrial Internet of Things): IIoT, on the other hand, focuses on the application of IoT
technologies in industrial and manufacturing settings. It involves the integration of sensors,
communication networks, and data analytics into industrial processes and machinery to enhance
efficiency, productivity, and decision-making. IIoT enables industries to monitor equipment
performance, optimize production processes, and even predict maintenance needs to minimize
downtime.

Key Features of IIoT:

 Industry-specific applications in manufacturing, energy, agriculture, and more.

 Integration of sensors and data analytics in industrial machinery and processes.
 Focus on improving operational efficiency, reducing downtime, and increasing safety.
 Data collected often used for predictive maintenance, process optimization, and supply chain
management.

In essence, while both IoT and IIoT involve the interconnection of devices for data exchange,
IoT is generally associated with consumer-oriented applications, while IIoT is centered around
industrial and manufacturing contexts, focusing on optimizing processes and increasing
efficiency in the business and production environment.
 Industry 4.0

Six principles of Industry 4.0

The principles of Industry 4.0 are often considered to be the foundational concepts that guide the
transformation of manufacturing and industrial processes in the fourth industrial revolution.
These principles reflect the core characteristics and goals of Industry 4.0. While there might be
slight variations in how these principles are articulated, here are six commonly recognized
principles:

1. Interoperability:
o Interoperability refers to the ability of various devices, systems, and components to
communicate and work together seamlessly. In an Industry 4.0 context, this involves
creating an integrated ecosystem where machines, processes, and data can be easily
connected and shared across different parts of the production process.

2. Virtualization:
o Virtualization involves creating digital models or replicas of physical objects, processes,
and systems. These digital representations allow for simulations, testing, and
optimization of processes without the need for physical prototypes. Virtualization helps in
making informed decisions, improving efficiency, and reducing the risk of errors.

3. Decentralization:
o Decentralization entails distributing decision-making processes across various levels of
an organization and across connected devices. This principle empowers autonomous
systems and devices to make localized decisions based on real-time data.
Decentralization supports agility and responsiveness in production processes.

4. Real-Time Data:
o Real-time data collection and analysis are essential in Industry 4.0. Sensors embedded in
machines and processes continuously gather data, which is then processed and
analyzed in real-time. This enables rapid decision-making, process optimization, and
predictive maintenance.

5. Service Orientation:
o Service orientation focuses on providing customized solutions and value-added services
to customers. In Industry 4.0, production processes can be reconfigured and adapted to
meet specific customer demands, allowing for greater flexibility and customization in
manufacturing.

6. Modularity:
o Modularity involves designing systems and processes as modular units that can be easily
assembled, disassembled, or replaced. This modular approach enables quick adaptation
to changing requirements and promotes scalability in production systems.

These principles collectively shape the transformation of traditional manufacturing processes

into more connected, intelligent, and efficient Industry 4.0 systems. Organizations that embrace
these principles can benefit from increased productivity, improved quality, reduced costs, and
enhanced agility in responding to market demands.
 Industry 4.0
How to leverage the principles (Cyber Physical systems, Interoperability,
Virtualization, Decentralization, Real-Time Capability, Service orientation and
Modularity) to identify & implement relevant technology pillars.

Leveraging the principles of Industry 4.0 to identify and implement relevant technology pillars
involves a strategic approach to integrating advanced technologies into your manufacturing and
industrial processes. Here's a step-by-step guide on how to do it:

1. Assessment and Alignment:

o Start by assessing your current processes, systems, and technologies. Identify areas that
can benefit from Industry 4.0 principles.
o Align your business goals and objectives with the principles of Industry 4.0. Determine
what specific outcomes you aim to achieve, such as increased efficiency, reduced
downtime, improved quality, or enhanced customization.

2. Technology Pillar Identification:

o Each principle corresponds to specific technology pillars that can be implemented
to achieve the desired outcomes. Identify the technology pillars that align with
your objectives. For each principle:
 Cyber-Physical Systems: Implement IoT devices, sensors, and actuators to
connect physical systems with digital counterparts.
 Interoperability: Integrate communication protocols and standards that enable
different devices and systems to exchange data seamlessly.
 Virtualization: Deploy digital twins and simulation tools to create virtual models
for testing and optimization.
 Decentralization: Implement edge computing to enable autonomous decision-
making at the device level.
 Real-Time Capability: Employ real-time data analytics and processing to enable
quick decision-making and process adjustments.
 Service Orientation: Implement modular software architectures and customer-
focused customization.
 Modularity: Design processes and systems with modular components that can
be easily reconfigured.

3. Technology Selection:
o Research and select specific technologies that align with the identified pillars. Consider
factors such as scalability, compatibility with existing systems, security, and future
expansion.

4. Pilot Projects:
o Start with pilot projects to test the selected technologies in controlled environments. This
helps you understand how the technologies interact with your processes and how they
contribute to achieving your objectives.

5. Data Collection and Analysis:

o Leverage real-time data collection and analytics to monitor the performance of the
implemented technologies. Use this data to measure the impact on efficiency, quality,
and other relevant metrics.

6. Iterative Approach:
o Industry 4.0 implementation is an ongoing process. Continuously gather feedback from
your pilot projects and initial implementations. Use this feedback to refine your strategies
and make necessary adjustments.
 Industry 4.0
7. Training and Workforce Development:
o Train your workforce to use and manage the new technologies effectively. Emphasize the
benefits and how the technologies align with the organization's goals.

8. Scaling Up:
o Once the pilot projects prove successful, scale up the implementation across different
parts of your organization. Ensure that the technologies are integrated seamlessly to
achieve maximum efficiency and value.

9. Continuous Improvement:
o Maintain a culture of continuous improvement. Regularly assess the impact of the
implemented technologies and seek opportunities for further optimization.

10. Collaboration and Partnerships:

o Collaborate with technology providers, consultants, and other organizations that
specialize in Industry 4.0 solutions. They can offer expertise and support in implementing
complex technologies.

Remember that each organization's Industry 4.0 journey will be unique, and the technology
pillars you choose to implement will depend on your specific goals, processes, and resources. It's
important to remain adaptable and open to adjustments as you navigate the transformative
process of Industry 4.0 implementation.

Briefing and application – Nine Technological Pillars of Industry 4.0

The nine technological pillars of Industry 4.0 are a comprehensive framework proposed by the
German Research Center for Artificial Intelligence (DFKI) that align with the principles of
Industry 4.0. These pillars represent the key technology areas that collectively enable the
transformation of manufacturing and industrial processes. Here are the nine technological pillars:

1. Horizontal Integration:
o This pillar focuses on connecting different stages of the value chain within an
organization. It involves integrating various processes, systems, and functions
horizontally to enable seamless data flow and collaboration.

2. Vertical Integration:
o Vertical integration involves connecting the various hierarchical levels within an
organization, from shop floor to top management. It enables data exchange and
communication between different levels of decision-making.

3. IoT (Internet of Things):

o The IoT pillar involves embedding sensors, devices, and machines with connectivity to
collect and exchange data. This data is used for real-time monitoring, analysis, and
decision-making.

4. Digital Twin:
o A digital twin is a virtual representation of a physical asset, process, or system. It enables
simulations, testing, and optimization, allowing for better understanding and prediction of
real-world behavior.

5. Additive Manufacturing (3D Printing):

 Industry 4.0
o Additive manufacturing involves building objects layer by layer using 3D printing
technology. It offers customization, rapid prototyping, reduced waste, and more complex
geometries.

6. Cloud Computing and Services:

o Cloud computing provides scalable and flexible storage and processing capabilities. It
allows organizations to access and analyze large amounts of data without requiring
extensive local infrastructure.

7. Augmented Reality (AR) and Virtual Reality (VR):

o AR and VR technologies overlay digital information onto the physical world. They
enhance training, maintenance, design, and visualization processes.

8. Big Data and Analytics:

o Big data refers to the vast amount of data generated by connected devices and systems.
Analytics tools extract valuable insights from this data, enabling informed decision-
making and process optimization.

9. Cybersecurity and Privacy:

o As connectivity increases, ensuring the security and privacy of data becomes crucial.
This pillar involves implementing measures to protect data, systems, and networks from
cyber threats.

These nine technological pillars collectively form the foundation of Industry 4.0, enabling
organizations to create smarter, more efficient, and interconnected manufacturing and industrial
processes. Each pillar addresses a specific aspect of the transformation and contributes to the
overall vision of Industry 4.0.

Application and use case studies of I 4.0 technological components in different

application.

Certainly! Industry 4.0 technological components can be applied across various industries and
applications to enhance processes, increase efficiency, and drive innovation. Here's how some of
the key Industry 4.0 components can be applied in different contexts:

1. Manufacturing:
o IoT Sensors: Placing sensors on machines and equipment to monitor their performance,
track usage, and detect maintenance needs in real-time.
o Digital Twins: Creating virtual replicas of manufacturing processes to simulate and
optimize production before physical implementation.
o Additive Manufacturing: Using 3D printing to produce prototypes, customized parts,
and complex structures with reduced material waste.
o Big Data Analytics: Analyzing production data to identify trends, inefficiencies, and
areas for improvement in manufacturing operations.

2. Supply Chain Management:

o RFID and Sensors: Using RFID tags and sensors to track the location and condition of
goods in transit, ensuring visibility and monitoring of supply chain activities.
o Cloud Computing: Utilizing cloud-based platforms to share real-time data across supply
chain partners, improving coordination and reducing lead times.
o Blockchain: Implementing blockchain technology to create secure and transparent
supply chain records, enhancing traceability and accountability.
 Industry 4.0
3. Energy and Utilities:
o IoT Sensors: Deploying sensors in energy systems to monitor usage, detect anomalies,
and optimize energy consumption.
o Data Analytics: Analyzing energy consumption patterns to identify opportunities for
energy efficiency improvements.
o Smart Grids: Integrating sensors, automation, and data analytics in electricity grids to
enhance grid stability and accommodate renewable energy sources.

4. Healthcare:
o IoT Devices: Incorporating wearable health devices and sensors to monitor patients' vital
signs and health conditions remotely.
o Telemedicine: Using video conferencing and communication technologies to enable
remote consultations and diagnosis.
o Big Data and Analytics: Analyzing patient data to predict health trends, personalize
treatment plans, and improve patient outcomes.

5. Agriculture:
o IoT Sensors: Placing sensors in fields to monitor soil moisture, temperature, and nutrient
levels for optimized irrigation and crop management.
o Drones: Using drones to capture aerial imagery and analyze crop health, allowing for
early detection of pest infestations or nutrient deficiencies.
o Data-driven Decision Making: Using data analytics to determine optimal planting and
harvesting times, leading to increased yields and reduced waste.

6. Automotive:
o Smart Manufacturing: Implementing flexible production lines that can quickly adapt to
different vehicle models and customization options.
o AR and VR: Using augmented reality for remote maintenance support and virtual design
reviews in the automotive design and manufacturing processes.
o Connected Vehicles: Embedding vehicles with IoT sensors and connectivity for real-
time diagnostics, predictive maintenance, and enhanced driver experiences.

These examples highlight the versatility of Industry 4.0 components across different industries.
By integrating these components into specific applications, organizations can achieve greater
efficiency, accuracy, and innovation in their processes, ultimately driving growth and
competitive advantage.

AR / VR / MR / Digital Twins

AR (Augmented Reality), VR (Virtual Reality), MR (Mixed Reality), and Digital Twins are
advanced technologies that play significant roles in various industries, from manufacturing to
healthcare, entertainment to education. Each of these technologies has unique characteristics and
applications. Let's explore each of them:

1. Augmented Reality (AR):

o AR overlays digital information, such as images, text, or animations, onto the real-world
environment. This digital content is typically viewed through devices like smartphones,
tablets, or AR glasses.
o AR enhances the real world by providing additional context, information, or visuals to
users.
o Applications: AR is used in maintenance and repair tasks, remote assistance, training,
marketing, navigation, and interactive learning experiences.
 Industry 4.0
2. Virtual Reality (VR):
o VR immerses users in a fully digital environment through specialized headsets. Users are
isolated from the physical world and can interact with the virtual environment.
o VR provides a simulated experience that can be entirely different from reality.
o Applications: VR is used for gaming, simulations, training, virtual tours, architectural
visualization, and therapeutic applications.

3. Mixed Reality (MR):

o MR blends elements of both AR and VR. It allows digital content to interact with the real
world and vice versa.
o MR headsets, like Microsoft's HoloLens, enable users to interact with digital objects in
their physical surroundings.
o Applications: MR is used for product design, prototyping, collaborative work, medical
visualization, and spatial computing.

4. Digital Twins:
o A digital twin is a virtual representation of a physical object, process, or system. It
enables monitoring, analysis, and simulation of the real-world counterpart.
o Digital twins help optimize performance, predict maintenance needs, and make informed
decisions.
o Applications: Digital twins are used in manufacturing (for process optimization), IoT (for
remote monitoring), healthcare (for patient simulations), and more.

In summary:

 AR (Augmented Reality) overlays digital information onto the real world to provide enhanced
context and interactivity.
 VR (Virtual Reality) immerses users in a fully digital environment, isolating them from the
physical world.
 MR (Mixed Reality) blends elements of AR and VR, allowing digital and physical elements to
interact.
 Digital Twins are virtual representations of physical objects or systems used for monitoring,
analysis, and simulation.

These technologies have the potential to revolutionize industries by improving communication,

training, visualization, problem-solving, and efficiency across a wide range of applications.

Briefing on AI (Artificial Intelligence) / ML (Machine Learning) / DL (Deep

Learning)

Certainly, I'd be happy to provide some information about AI (Artificial Intelligence), ML

(Machine Learning), and DL (Deep Learning):

1. Artificial Intelligence (AI): AI refers to the simulation of human intelligence processes

by machines, particularly computer systems. These processes include learning (acquiring
information and rules), reasoning (using rules to reach conclusions), problem-solving,
perception (using sensory inputs to interpret and understand the world), and natural
language understanding and generation. AI can be classified into two categories: Narrow
or Weak AI, which is designed for a specific task (e.g., voice assistants, recommendation
systems), and General or Strong AI, which would have human-like intelligence and the
ability to perform any intellectual task.
 Industry 4.0
2. Machine Learning (ML): Machine Learning is a subset of AI that involves the use of
algorithms and statistical models to enable computers to improve their performance on a
specific task through learning from data. Instead of being explicitly programmed, a
machine learning model learns patterns and relationships from the data it is trained on.
The primary types of machine learning are supervised learning (training on labeled data),
unsupervised learning (finding patterns in unlabeled data), and reinforcement learning
(learning through trial and error based on rewards).
3. Deep Learning (DL): Deep Learning is a subset of machine learning that focuses on
neural networks with multiple layers, also known as deep neural networks. These
networks attempt to simulate the behavior of the human brain's interconnected neurons,
allowing them to learn and make decisions in a hierarchical manner. Deep Learning has
led to significant advancements in fields like computer vision, natural language
processing, and speech recognition. Convolutional Neural Networks (CNNs) for image
analysis and Recurrent Neural Networks (RNNs) for sequence data are common
architectures within deep learning.

In summary, AI is the broader concept of machines performing tasks that require human
intelligence, ML is a subset of AI that involves machines learning from data, and DL is a subset
of ML that involves deep neural networks to model complex patterns and relationships in data.
These fields have seen rapid development and innovation in recent years, leading to applications
in various industries and domains.

Preventive Maintenance (PM) vs Condition Based Maintenance (CBM)

Preventive Maintenance (PM) and Condition-Based Maintenance (CBM) are two different
approaches to maintaining and managing equipment and systems in various industries. Here's a
breakdown of each approach:

1. Preventive Maintenance (PM): Preventive Maintenance involves scheduled and routine

maintenance activities performed on equipment and systems to prevent potential failures
or breakdowns. These activities are based on a predetermined schedule and are carried
out regardless of the actual condition of the equipment. The primary goal of PM is to
reduce the likelihood of unexpected downtime and extend the operational life of
machinery.

PM typically involves tasks like inspections, lubrication, cleaning, calibration, and

component replacement according to manufacturer guidelines or industry best practices.
It's based on the assumption that certain components have a predictable lifespan, and
replacing them before they fail can minimize disruptions and maintain overall system
reliability.

While PM can be effective at preventing some failures, it may lead to unnecessary

maintenance if components are replaced before they reach the end of their useful life.
This can result in higher maintenance costs and resource allocation.

2. Condition-Based Maintenance (CBM): Condition-Based Maintenance, also known as

Predictive Maintenance, relies on real-time data and monitoring to make maintenance
decisions. Instead of adhering to a fixed schedule, CBM involves continuously
 Industry 4.0
monitoring the actual condition of equipment using sensors, data analysis, and other
monitoring techniques.

CBM aims to detect early signs of deterioration, wear, or anomalies that indicate
potential failures. By collecting and analyzing data on factors such as vibration,
temperature, pressure, and other relevant parameters, maintenance activities are
scheduled based on the actual condition of the equipment. This approach allows
maintenance teams to perform interventions only when they are truly needed, reducing
unnecessary downtime and maintenance costs.

CBM is particularly useful for critical systems where unexpected failures can have
significant consequences. It optimizes maintenance efforts by addressing issues before
they escalate and is often considered more cost-effective compared to routine PM.

In summary, Preventive Maintenance is a scheduled approach that involves performing

maintenance tasks at predetermined intervals to prevent failures, while Condition-Based
Maintenance relies on real-time data and monitoring to detect potential issues and perform
maintenance only when needed. CBM is generally considered more efficient and cost-effective
in industries where downtime and disruptions are costly.

How to leverage VR / AR in HR Induction Trainings or TPM – Jishu-Hozen (JH) or

Improving maintenance KPIs

Jishu-Hozen (JH), also known as Autonomous Maintenance, is a concept and practice that
originates from the Total Productive Maintenance (TPM) framework. TPM is a comprehensive
approach to maintenance management that aims to maximize the effectiveness of equipment and
machinery in a manufacturing or production environment.

Jishu-Hozen specifically focuses on empowering frontline operators and workers to take

ownership of the maintenance and care of their equipment. The term "Jishu-Hozen" translates to
"autonomous maintenance" or "operator-led maintenance" in English.

Key principles and activities of Jishu-Hozen include:

1. Cleanliness and Inspection: Operators are responsible for keeping their work areas and
equipment clean and well-maintained. Regular inspections are conducted to identify and
address issues such as wear, leaks, or abnormalities.
2. Basic Equipment Care: Operators are trained to perform routine maintenance tasks,
such as lubrication, tightening bolts, and replacing worn-out parts. This helps prevent
deterioration and reduces the likelihood of unexpected breakdowns.
3. Early Problem Detection: Operators are encouraged to be vigilant and identify potential
problems as early as possible. This could involve noticing unusual sounds, vibrations, or
other signs of equipment issues.
4. Standardization of Procedures: Standard operating procedures are developed and
documented for routine maintenance tasks. This ensures consistency and reliability in
maintenance practices.
 Industry 4.0
5. Skill Development: Operators receive training to develop the necessary skills for basic
maintenance tasks and inspections. This empowers them to take proactive measures to
keep equipment in good condition.
6. Root Cause Analysis: If an issue is identified, operators may perform initial
investigations to determine the root cause of the problem. This information can be
valuable for further improvements and preventive measures.

The goal of Jishu-Hozen is to create a culture of continuous improvement and ownership among
operators, where they actively contribute to the overall equipment reliability and operational
efficiency. By involving operators in the maintenance process, Jishu-Hozen aims to reduce
downtime, improve equipment performance, and foster a sense of responsibility and teamwork.

Jishu-Hozen is one of the key pillars of the TPM philosophy, which also includes activities like
Planned Maintenance, Quality Maintenance, and Focused Improvement. Overall, TPM aims to
optimize equipment effectiveness, reduce waste, and improve overall production efficiency.

Improving maintenance KPIs

Improving maintenance Key Performance Indicators (KPIs) involves implementing strategies

and practices to enhance the reliability, availability, and efficiency of equipment and systems.
Here are some steps and approaches you can take to improve maintenance KPIs:

1. Data-Driven Approach: Collect and analyze data related to equipment performance,

downtime, maintenance activities, and failure patterns. Use this data to identify trends,
root causes of failures, and areas for improvement.
2. Condition Monitoring: Implement condition-based monitoring using sensors and data
analysis to detect early signs of equipment degradation or abnormalities. This allows for
timely maintenance interventions and reduces unexpected downtime.
3. Predictive Maintenance: Utilize predictive maintenance techniques to forecast
equipment failures based on data analysis. This helps schedule maintenance activities
before breakdowns occur, minimizing disruptions.
4. Reliability-Centered Maintenance (RCM): Adopt RCM principles to prioritize
maintenance tasks based on the criticality of equipment and potential impact on
operations. Focus on maintaining the most critical components and systems.
5. Root Cause Analysis: Investigate the root causes of failures to prevent recurring issues.
Implement corrective actions to address underlying problems and improve equipment
reliability.
6. Total Productive Maintenance (TPM): Implement TPM practices, including Jishu-
Hozen (autonomous maintenance), Planned Maintenance, and other pillars, to involve
operators in maintenance tasks and improve overall equipment effectiveness.
7. Spare Parts Management: Optimize inventory management of spare parts. Ensure that
critical components are readily available while minimizing excess inventory to reduce
costs.
8. Reliability Improvement Programs: Develop initiatives to systematically address
reliability issues. This could involve targeted improvements to specific equipment or
systems based on data analysis.
 Industry 4.0
9. Benchmarking and Best Practices: Research and implement industry best practices for
maintenance. Benchmark against similar organizations to identify areas where you can
make improvements.
10. Training and Skill Development: Provide training to maintenance personnel and
operators to enhance their skills in performing maintenance tasks, inspections, and
troubleshooting.
11. Continuous Improvement: Foster a culture of continuous improvement within the
maintenance team. Encourage feedback, suggestions, and collaboration to identify and
implement efficiency-enhancing ideas.
12. Technology Adoption: Embrace new technologies such as IoT, AI, and machine
learning to optimize maintenance processes. These technologies can enable better data
analysis and decision-making.
13. Key Performance Indicator Selection: Choose the right KPIs that align with your
maintenance goals. Common KPIs include Mean Time Between Failures (MTBF), Mean
Time to Repair (MTTR), Overall Equipment Effectiveness (OEE), and Maintenance Cost
as a Percentage of Asset Replacement Value.

Remember that improving maintenance KPIs is an ongoing process that requires collaboration,
continuous learning, and adaptation to changing conditions. It's essential to involve all
stakeholders, including maintenance teams, operators, and management, to achieve sustained
improvements.

1. Use Case Study:

1. Use of LoRaWAN technology in Smart Building Management System / Energy
Management / Utilities
2. How to identify scope of implementation of DRA / Industry 4.0 in your work area
/ function / across company
3. IIOT : Emergency and Safety of Workplace
4. How to collect, visualize, analyse, monitor & autonomous control of process and
product parameters for ZERO Defect
2. How to identify organisational pain area and prioritizing implementation scope of I4.0
3. Competency Building and skill sets required for I4.0 and how to enhance competency of
current manpower / team members.

Benefits:

1. To enable participants to understand Industry 4.0 concept, principles, and technologies.

2. To enable them the skill to identify the pain areas and relevant technological components
to be implemented.
3. To start implementing the concepts learnt, relate to their organization.
4. To learn from actual industry case studies on Industry 4.0
5. To learn basic principles, benefits, and challenges of Industry 4.0 at the end of the
workshop
 Industry 4.0
Society 5.0/ IOT 5.0

IT and OT

Control Centralization – Industry 3.0, Rule base , repetitive job , Industrial robots in fencing.

Automation

Decentralization- Industry 4.0, Self-learning, coborts- Collaborative robots- Tooth paste,

autonomous

AGV- Auto guided Vehicle

Amazon's Smart Warehouse

https://youtu.be/IMPbKVb8y8s

AR- lenskart, nike- supper imposing of varual image in physical world

VR- disconnected from physical world

Hero motor cop. neem rana

Okuma Japanese company

GS pharmaceuticals – digital twin

LPWAN – Low power wide area Network

LORA – Low power Long Range

LoRAWAN – Communication Protocall

Intranet

IGSCS

GSM Internet

Python

Deep thinks networks DTN- Open

Application configure possible

DH21 senser