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INDUSTRY 4.0 CAN THE FOURTH INDUSTRIAL REVOLUTION SAVE FRENCH INDUSTRY? T h e co n d i t i o n o f Fre n c h i n d u st r y i s wo r r y i n g : t h e i nve st m e n t g a p i s about €40 billion,the stock of industrial machinery is some ten years older than that of Germany, and factory closures are a regular event. Faced with this situation, the Ministry for the Economy and Finance is currently paying close attention to «Industry 4.0», a German industrial project. Can this concept, which holds the promise of a fourth industrial revolution, save French industry? « IN DU ST RY 4 . 0 » : A P R OJ EC T “ M A D E I N G ER M A NY ” The concept of « Industry 4.0 » defines a new way to organize factories, also known as «Smart Factories» or « Intelligent Factories », in order to better serve customers through increased AUTHORS flexibility in production and resource optimization. « Industry 4.0 » is an industrial project, which was launched at the industrial technology show, CeBIT, in Hanover, in 2010. It was officially introduced and supported by the chancellor, Angela Merkel, at that same show in 2012. The project is a key part of the German government’s high-tech strategy, in which the country’s industrial trade associations are heavily involved. Among European countries, France is a latecomer in terms of interest in this concept. After Germany launched the « Industry 4.0 » project in 2010, the UK launched its own PATRICIA VERRIÈRE - CUENOT [email protected] CAROLINE QUENEDEY [email protected] program in 2011, the « High-Value Manufacturing Catapult », followed in 2012 by Italy and its « Fabbrica del futuro ». The French government launched its « Usine du futur » (Factory of the Future) initiative in September 2013, as part of a series of 34 plans in its Nouvelle France Industrielle (New Industrial France) strategy. However, the condition of French industry is worrying. French Ministry believes that France is lagging behind in investment to a sum of about €40 billion. The stock of industrial machinery is estimated to be, on average, some ten years older than that of Germany. Can « Industry 4.0 » , which holds the promise of a fourth industrial revolution, save French industry? WHAT IS «INDUSTRY 4.0»? W H Y DOES I T R EP R ESENT A N IN D U ST RI A L B R EA KT H R O U G H ? Intercommunication between the different new ways of organizing production across Our daily lives have been transformed by « Industry 4.0 » factory. It enables robots the entire value chain. « Industry 4.0 » has smartphones and the internet. They allow and systems to access data (using sensors, been described as the fourth industrial revo- us, in particular, to communicate and share controllers, and simulations) in real-time in lution. The first industrial revolution was information with people or objects. Why order to react as quickly as possible to an triggered in the 1780s by the arrival of the not adapt these technologies for use in event (such as an incident, modification, or first examples of mechanized production, factories? This is the direction being taken non-compliance). This use of real-time infor- driven by the invention of the steam engine. by Germany with its « Industry 4.0 » pro- mation and robotic systems is set to disrupt The second industrial revolution began in ject. Observing the increase in competition modes of production and the way manufac- about 1850 with the invention of electricity from emerging economies, especially China, turing is organized. This is something that and mass production. In the 1970s, a third Germany wants to secure its position, by will impact all types of roles, from engineers industrial revolution began, the era of auto- entering a new industrial era. It is crucial for to maintenance operators, and will also mated production with the development of the survival of its industry that this repre- change the physical locations of factories. electronics, the first automation, and indus- sents a real breakthrough, which will provide trial information technology. A fourth indus- it with a competitive advantage over time. The « Industry 4.0 » project aims to develop trial revolution is now beginning, personified actors and objects connected to the production line is the central feature of the As a result, « Industry 4.0 » constitutes a real breakthrough based on three major in the internet of things and the cloud, for Often presented as the digitization of busi- technological innovations: collaborative the manufacture of products incorporating ness, this concept needs to be seen through robotics, self-adaptation of production intelligent systems such as simulation sys- a more ambitious lens to ensure a real revo- systems (with smart, connected sensors), tems and sensors. lution. Digitalizing 2D drawings for design, and the use of augmented reality. manufacture, and maintenance is not suffi- HOW DO ES AN « IND U ST RY 4 . 0 » FACTORY O PERATE? cient anymore. Virtualization involves the The « Industry 4.0 » factory operates accor- duction and maintenance processes. ding to six key principles: transition to 3D models for design, product modification and the management of pro- In addition, it is essential to integrate the The factory is virtualized in order to simulate and monitor products, processes and the production environment in 3D, use of connected devices, cloud computing, // Its systems are interoperable: they have the ability to communicate and interact with each other, workstations, in real-time. // Decisions are decentralized: with cyber-physical systems taking autonomous decisions, // Analysis and decision-making take place in real-time, through continuous and instantaneous communication, // It is service-oriented: with better maintenance, and can offer new types of services, // It is modular: it adapts rapidly to changing demand. // augmented reality, 3D printing, etc. The goal is to connect together all «smart» objects so that they can interact, with each other and 2 A R E T H I NG S L I M I T ED TO A TECHNO LO G I C A L B R EA KT H R O UG H? Reducing « Industry 4.0 » to a technological breakthrough would be a mistake. By involving trade associations and the unions, the German project has not fallen into this trap. The impacts on the way work is organized, and on skills and disciplines, are highly significant. Some illustrations of this are: INDUSTRY 4.0 // // // // // Manufacturing processes are simulated at the product design stage. The technical activities carried out by operators, in terms of manufacturing and maintenance, can be simulated. As a result, workplace ergonomics are greatly improved, either transferring difficult tasks to robots or by modifications to the working environment. In conclusion, « Industry 4.0 » is a step Operators are equipped with connected devices, such as tablets or glasses, which allow them to see an augmented reality. These devices can be used to facilitate maintenance operations and quality control, for example. The role of an operator, therefore, involves an increasing degree of management and control activity, and less and less manual labor. to senior management. The role of management is also strengthened. Decision making is decentralized along the production line, with tools being developed to assist in management and control. sectors have understood this fact and have The coexistence between people and machines in the factory impacts behavior. In an environment where robots and systems are increasingly used, the role of the manager in creating and maintaining team spirit and good communication becomes essential. As a result, the skills are evolving too: the transition from 2D to 3D, the use of connected objects, and decision-making skills. These developments are accompanied by the use of training plans and the creation of expert-communities to share best practice. change in the way things are designed and produced. This is a project based on global considerations and involving all operational functions (production, supply chain, engineering, maintenance, etc.), but also the support functions (finance, human resources, « A European dynamic to reorganize industrial production. » and information systems), and at all levels of the hierarchy: from operational team leaders to be customized without additional costs « Industry 4.0 » is, therefore, an opportunity for France to strengthen its industrial base and maintain, or even expand, the number of future jobs in industrial sectors. It is an issue of survival for our competitiveness clusters such as aerospace, automotive, and railways; the main players in these or time input. Product quality is improved by the immediate correction of defects that arise during manufacture through increased use of automatic controls. For example, the incorporation of RFID into all components improves the traceability and control of assemblies throughout the production life cycle. The analysis of product configuration already launched initiatives to this end. and its associated real-time operating data W H AT AR E T H E EX P EC T ED B E N E F IT S ? triggered automatically. « Industry 4.0 » aims to make products both more attractive and more affordable for customers through the development of product customization and a reduction in the time to deliver products to market, while, at the same time, increasing quality and associated services. In summary, with « Industry 4.0 » , we are moving from mass production to customized large-scale production and an explosion in services. allows preventive maintenance actions to be Companies also benefit, internally, from this revolution through better communication and coordination between functions. The logistics system can anticipate, for example, a request for parts as a result of sensors monitoring the levels of inventory and activity in the production process. The management of data in real-time speedsup decision-making for operators but also for machines, which can automatically take action, according to the information they are collecting and that provided by other The first beneficiary is, therefore, the cus- machines. tomer. The implementation of intelligent modular production lines allows products The different industrial revolutions 1.0 2.0 3.0 3 4.0 Employees are positively impacted as a result of improvements to their working conditions. The use of robots has already At the heart of this model are: // partially freed people from repetitive and tedious tasks. Ergonomics will be further improved through systems for the gripping and automatic positioning of items on the // The MES (Manufacturing Execution System), which ensures that information can be transmitted and fed back in real-time to support production, // Augmented Reality to support quality control, maintenance, repair or training. factory floor which use data from digital models. However, we need to look beyond this to make use of robots, and other possibilities for automation, as tools that serve employees. The introduction of connected objects will be accompanied by an increase in operators’ skills, making them more ver- PLM (Product Lifecycle Management), which provides the definition, management, and accessibility of information generated and processes that support design, satile and available to monitor tasks, and to The integration of PLM/MES/Augmented be able to provide feedback to help ensure Reality solutions is a prerequisite for continuous process improvement. continuity in virtual models, from design Finally, the financial impact on compa- perceive as attractive. If a competitive and attractive model is to be built, which goes beyond purely technological aspects, the human dimension must not be overlooked. to production. nies is considerable, due to the significant The implementation of an « Industry 4.0 » investments involved, but also in terms of factory project starts with defining the the expected gains. Airbus, for example, business’s strategy and sharing this with envisages a 50% reduction in its production all functions. In fact, such a project actually costs. requires considerable collective effort, which is delivered through a shared vision of the HOW CAN IT BE IMPLE ME N T E D? To be on the starting grid in this revolution, it is essential to have a comprehensive and consistent virtual 3D-model product/ process in place, fully digitized and shared across all functions, partners, and suppliers. This virtual model manages all the information throughout the lifecycle of the product. It allows the simulation of product behavior, the production system and its maintenance, and associated services. challenges and transformation required. To attempt such a transformation and ensure that the necessary change takes place, rigorous scoping is required which addresses all the relevant dimensions (technological, organizational, human and financial). An « Industry 4.0 » factory will need tools and technological innovations, but also ergonomic improvements to be proposed to the various internal and external actors, in order to create an environment that they will www.wavestone-advisors.com Wavestone is a consulting firm, created from the merger of Solucom and Kurt Salmon’s European Business (excluding retails and consumer goods outside of France). Wavestone’s mission is to enlighten and guide their clients in their most critical decisions, drawing on functional, sectoral and technological expertise. 2016 I © WAVESTONE