Industry 4.0: Ignore the hyperbole, believe the hype

In the late 1800s noted promoter P.T. Barnum used every means at his disposal to get his message across. Advertising, self-promotion, and blatant lying were all part of Barnum’s bag of tricks. So too were misdirection, exaggeration, and bloviation.

At the end of the day, it was all about the hyperbole.

His over-the-top pronouncements drew everyone’s attention, which led to large crowds, which led to some real money. The 19th century shyster/showman had figured out the formula for creating hype.

The hype today in the manufacturing sector revolves around Industry 4.0, with most manufacturers, especially small and medium-sized shops, still wondering what it is and how it can help them. According to a recent KPMG study, projections for the total market revenues that will be generated by Industry 4.0 run into the trillions of dollars. Expectations from all over the sector are high.

Each part of this new manufacturing trend can be valuable, even if only a portion of its full potential is used.

The problem is that manufacturing executives mainly work on real-world production issues, and many simply don’t have the time to spend separating fact from fiction. They want a clear picture of the current technology and how it can ease production roadblocks, create better margins, and solve issues that arising on the shop floor.

Here are three simple ways to implement change in your shop using the theory of Industry 4.0:

1. Use your “big data” to predict and stop failures before they occur. Big data can be used for something as routine (and necessary) as predictive maintenance. By gathering and analyzing machine tool data from new sensors in real time, maintenance can be planned well ahead of any potential failure.

2. Use industrial internet of things (IIoT) sensors to track energy consumption. With electricity prices high, it’s important to note the energy-related costs accrued at each machine or station. Purchasing energy-efficient equipment like pumps and compressors that only turn on when needed is a good first step.

3. Invest in next-level robots. Autonomous robots and collaborative robots (cobots) are two relatively new automation systems that can save workers from repetitive, strenuous activities. Autonomous, self-driving robots are increasingly being used for many warehousing tasks, while cobots, which are designed to share a workspace with a shop worker, have many applications, including machine tending, assembly, and packaging.

While interest in Industry 4.0 remains high, few shops are transforming into a “shop of the future.”

It’s time to change that.