UNIT-1

Introduction to Mechanical Systems

What is Industry 4.0?
• Industry 4.0, which is synonymous with smart manufacturing, is the realization of the digital
transformation of the field, delivering real-time decision making, enhanced productivity, flexibility
and agility to revolutionize the way companies manufacture, improve and distribute their products.
• Industry 4.0 technologies are changing manufacturing
• Manufacturers are integrating new technologies, including Internet of Things (IoT), cloud
computing and analytics, and AI and machine learning into their production facilities and
throughout their operations.
• Smart factories are equipped with advanced sensors, embedded software and robotics that collect
and analyze data and allow for better decision making. Even higher value is created when data from
production operations is combined with operational data from ERP, supply chain, customer service
and other enterprise systems to create whole new levels of visibility and insight from previously
siloed information.
• These digital technologies lead to increased automaion, predictive maintenance, self-optimization of
process improvements and, above all, a new level of efficiencies and responsiveness to customers
not previously possible.
• Developing smart factories provides an incredible opportunity for the manufacturing industry
to enter the fourth industrial revolution. Analyzing the large amounts of big data collected
from sensors on the factory floor ensures real-time visibility of manufacturing assets and can
provide tools for performing predictive maintenance in order to minimize equipment
downtime.
• Using high-tech IoT devices in smart factories lead to higher productivity and improved
quality. Replacing manual inspection business models with AI-powered visual insights
reduces manufacturing errors and saves money and time. With minimal investment, quality
control personnel can set up a smartphone connected to the cloud to monitor manufacturing
processes from anywhere. By applying machine learning algorithms, manufacturers can
detect errors immediately, rather than at later stages when repair work is more expensive.
• Industry 4.0 concepts and technologies can be applied across all types of industrial
companies, including discrete and process manufacturing, as well as oil and gas, mining and
other industrial segments
• Characteristics of a smart factory
• Data analysis for optimal decision makingEmbedded sensors and
interconnected machinery produce a significant amount of big data for
manufacturing companies. Data analytics can help manufacturers
investigate historical trends, identify patterns and make better
decisions. Smart factories can also use data from other parts of the
organization and their extended ecosystem of suppliers and
distributors to create deeper insights. By looking at data from human
resources, sales or warehousing, manufacturers can make production
decisions based on sales margins and personnel. A complete digital
representation of operations can be created as a "digital twin."
10 manufacturing trends that are changing the industry

• Manufacturing has undergone a major digital transformation in the last few years, with technological
advancements, evolving consumer demands and the COVID-19 pandemic serving as major catalysts
for change. To maintain their competitiveness and overcome today’s challenges, manufacturers have
had to make agility and adaptability top priorities.
• 1. Digitalization and Industry 4.0
• Digitalization has had a profound impact on the manufacturing sector, enabling businesses to optimize
processes, improve quality and reduce costs. Industry 4.0—also known as the fourth industrial
revolution—is the latest phase of the manufacturing industry’s digital transformation. It integrates
advanced technologies—like the Internet of Things (IoT), artificial intelligence (AI) and
cloud computing—into an organization’s existing manufacturing processes.
• Industry 4.0 enables manufacturers to conduct real-time data collection and analysis for vast amounts
of data, providing them valuable insights into their operations.
• It also helps organizations more easily manage and maintain equipment, utilizing cloud storage and
facilitating communication between enabled equipment to create more flexible, agile manufacturing
systems that can adapt quickly to changes in demand.
• 2. Artificial intelligence (AI)
• One of the most significant benefits of artificial intelligence (AI) in manufacturing is its ability to analyze vast amounts of data in real-
time. With Industrial Internet of Things (IIoT) devices and sensors collecting data from machines, equipment and production lines, AI
algorithms can quickly process and analyze data to identify patterns and trends, helping manufacturers understand how production
processes are performing.
• Companies can also use AI to identify anomalies and equipment defects. Machine learning algorithms, for instance, can be trained to
identify patterns in the data and manage decision-making based on those patterns, allowing manufacturers to catch quality issues early in
the production process.
• Furthermore, AI can help manufacturers implement predictive maintenance systems and processes, streamline supply chain management,
and identify and address workplace safety hazards proactively.
3. 3D printing
• 3D printing, also known as additive manufacturing, is a rapidly growing technology that has changed the way companies design,
prototype and manufacture products. In smart factories, 3D printing is a popular tool for producing complex parts and components
quickly and precisely.
• Traditional manufacturing processes, like injection molding, can be limited by the complexity of a prototype’s part geometry, and they
may require multiple steps and operations to produce. With 3D printing, manufacturers can produce complex geometries in a single step,
reducing manufacturing time and costs.
• Additive manufacturing is particularly useful in industries such as aerospace, automotive and healthcare, where complex parts and
components are required. This technology also enables manufacturers to produce spare parts on-demand, reducing the need for large
inventories and improving supply chain efficiency.
• 4. Robotics and automation
• Robotics and automation have been transforming manufacturing for years now, and this
trend is only expected to continue. Robotic process automation has been a key driver of
smart manufacturing, with robots taking on repetitive and/or dangerous tasks like assembly,
welding and material handling.
• Robotics technology can perform repetitive tasks faster and with a much higher degree of
accuracy and precision than human workers, improving product quality and reducing
defects. Manufacturers can also integrate robotics with Industrial Internet of Things (IIoT)
sensors and big data analytics to create a more flexible and responsive production
environment.
• Ultimately, robotic automation can improve system efficiency, reduce errors, decrease
equipment downtime and increase worker safety in manufacturing operations. As an added
benefit, robots can work around the clock, providing manufacturers with the ability to
operate 24/7 and significantly increasing productivity.
• 5. Sustainable manufacturing
• Manufacturing processes often require large amounts of energy and water and can
often produce harmful waste and other by-products, so sustainability initiatives are
becoming an increasingly important factor in modern manufacturing. Today’s
consumers are more environmentally conscious than ever before, and governments
continue to implement regulations to reduce carbon emissions and protect the
environment. As a result, manufacturers are under pressure to mitigate the impacts
of climate change by pushing for carbon neutrality and minimizing their carbon
footprints.
• Companies engaging in sustainable manufacturing aim to reduce waste, conserve
resources and minimize the use of harmful substances by using renewable energy
sources, adopting circular economy principles and implementing eco-friendly
production processes.
• 6. Servitization
• Servitization is a business model that involves moving from selling products to providing services. In
the manufacturing industry, servitization involves offering after-sales services—such as maintenance,
repair and upgrades—to customers. This model can help manufacturers to build stronger relationships
with customers, increase customer loyalty and generate recurring revenue streams. Servitization also
enables manufacturers to differentiate themselves from competitors by offering value-added services
that enhance the customer experience. Furthermore, manufacturers can gain valuable insights into their
customers’ needs and preferences, which can inform product development and improve customer
satisfaction.
• 7. Reshoring
• Reshoring is the process of bringing manufacturing operations back to their home country from overseas
locations. This trend has gained momentum in recent years due to labor shortages, supply chain
disruptions, geopolitical risks and rising labor costs in overseas locations. Reshoring can provide several
benefits for manufacturing companies, including reduced transportation costs, improved quality control
and increased flexibility. Additionally, reshoring can help to create new jobs and support local
economies.
• 8. Extended reality
• Extended reality (XR) refers to technologies that merge the physical and digital worlds; for example, virtual reality (VR) and augmented reality
(AR). One of the chief benefits of XR is its ability to improve employee training and education and address worker skills gaps. XR technologies can
help manufacturers create immersive training simulations that help employees learn new skills and procedures in a controlled environment. As a
result, workers get real-time information and guidance, and companies get more productivity and fewer errors.
• On the consumer side, XR can enhance the customer experience by providing virtual product demonstrations and visualizations. It can also help
manufacturers design and develop better products for customers since designers can visualize and test products in a virtual environment before they
are mass-produced and sent to market.
• 9. Advanced materials
• As manufacturing processes have advanced, so too have manufacturing materials. Advanced materials like composites, ceramics and nanomaterials
are becoming the industry norm, as these materials offer increased strength and durability and improved thermal properties when compared to
traditional raw materials. Advanced materials have a variety of potential applications, including aerospace, automotive and healthcare
manufacturing. Composite materials, for instance, are helping manufacturers produce lightweight and fuel-efficient aircraft, while nanomaterials are
being used to develop new medical treatments.
• 10. Digital twins
• Digital twins have become an increasingly popular concept in the world of smart manufacturing. A digital twin—a virtual replica of a physical
object or system, equipped with sensors and connected to the internet—can collect data and provide real-time performance insights. In smart
factories, digital twins are used to monitor and optimize the performance of manufacturing processes, machines and equipment.
• By collecting sensor data from manufacturing equipment, digital twins can detect anomalies, identify potential problems, improve forecasting
capabilities and provide insights into how to optimize production processes. Manufacturers can also use digital twins to simulate scenarios and test
configurations before implementing them.
Sustainability
• The fourth industrial revolution, also labelled Industry 4.0, was beget with
emergent and disruptive intelligence and information technologies. These new
technologies are enabling ever-higher levels of production efficiencies. They
also have the potential to dramatically influence social and environmental
sustainable development. Organizations need to consider Industry 4.0
technologies contribution to sustainability.
• introduce a measures framework for sustainability based on the United
Nations Sustainable Development Goals; incorporating various economic,
environmental and social attributes. We also develop a hybrid multi-situation
decision method integrating hesitant fuzzy set, cumulative prospect theory and
VIKOR. This method can effectively evaluate Industry 4.0 technologies based
on their sustainable performance and application.