The production processes, which have been continuing since the day human beings started walking on the earth and which started with the “Industrial Revolution” after thousands of years, are going through a very different evolution process in the information age today. Industry 4.0, which came to the fore with digitalization, artificial intelligence, cloud systems and IoT finding more place in almost every field, carries the industry to the future.
The dazzling change experienced in production systems and industry for the last 250 years is witnessing a new transformation in the light of the technologies and innovations offered by the information age. The extraordinary rapid developments in the production, sharing and use of information throughout the 1900s offered us very different and new technologies such as smart robots, autonomous vehicles, artificial intelligence systems, and the internet of things at the end of the century. Traditional production methods used in different geographies of the world have become different with digitalization and have started to leave their place to autonomous systems today. This brought us to the brink of the new crossroads; Industry 4.0.
What does Industry 4.0 mean?
Industry 4.0 refers to a production model in which production models constantly communicate with each other and the concepts of technology and value chain form a unity and turn into cyberphysical systems. In this system, where digitalization is involved in almost every stage of the business, all devices are transformed into smart factories by talking to each other, and by keeping the whole process under control, they reach the output in this way. In Industry 4.0, where all devices communicate not only with each other but also with people working on production, everything becomes digital and the internet becomes the basic tool used in all steps. In this production model, unlike the previous ones, many advantages are offered in different layers, aiming for more serial, error-free, faster and more production. Since the systems are constantly monitored and monitored in Industry 4.0, malfunctions and errors are detected in advance and possible production disruptions are prevented. On top of that, since artificial intelligence systems are used so frequently, it is aimed to improve the self-identity of devices and improve their decision-making abilities. It is aimed to reduce carbon footprints by making production in a more environmentally friendly way. Resources are used more sparingly. High efficiency is achieved and all unnecessary steps are eliminated. Costs are reduced and flexibility is increased, leading to full time production. Since the system is fully adapted to digital, a continuous change and development process can be followed.
The factories of the future will be “Smart”
One of the biggest changes that digital transformation will make in our lives will be in production centers, workshops and factories. As a part of the dizzying change in technologies such as artificial intelligence, cloud systems, 5G, wi-fi and li-fi in recent years, factories continue to get smarter. Very few people will need arm strength. These factories, which almost do not even need light, will also eliminate all risks that may arise from human beings. Accordingly, these factories, which will create significant changes in terms of occupational health and safety, are also called “Dark Factories” because they work with the zero light principle.
These factories, where control mechanisms are provided completely digitally and many interconnected machines operate autonomously and produce, are expressed as the points where the most basic and advanced technology of the change, which is described as industry 4.0, emerges.
All processes in smart factories are kept under control 24 hours a day, 7 days a week by different technological systems. A communication system is activated without the need for human beings in these centers where production is almost never interrupted and machines operate in a clockwork order. This process, which operates autonomously and on its own, is controlled by a human at any time, and all data can be captured and processed as desired. Protecting human health, preventing possible injuries, accidents or deaths, and reducing humaninduced errors whenever possible lies behind the emergence of these factories and their increasing preference day by day.
Considered since the early 80’s
Although the idea of the Smart Factory may seem like an expression or formation from the new era, its history goes back to the early 1980s. At that time, factories with a large number of workers were in the majority, and a system that worked with semi-automatic, semi-human power was imagined as the basic idea. However, no factory could imagine a structure that was fully controlled by digital systems and operated autonomously as we understand it today. In order for this to be imagined and implemented, digitalization and, accordingly, Industry 4.0 would have to come into play. The reason behind the design of this structure and then its implementation lies in the excessive increase in consumption and the inability to keep up with the production speed and capacity. Factories that work with the logic of continuous production and do not need to rest, so to speak, because there is very little manpower, are designed to meet this consumption capacity.
Smart factories undoubtedly bring many benefits and completely change production systems. The first example of dark factories, which will intensify in the future with Industry 4.0, was held in China. In this factory, which produces mobile phone modules, many robot systems have been installed that can do the job of 6-8 workers alone. In addition, while the number of workers in the factory was 650 before this technique was adopted, the number decreased to 60 after the system.
The dark factory technique has already gained popularity and signals that it will be used in the factories of big brands day by day. In the near future, factories with this system will make a difference to their competitors by producing continuously and without stopping, and they will add new values to the system. Although the number of dark factories is few today, it seems to be among the concepts that we will hear frequently in the developing technology and production sector with the clue and foresight it gives us about the future. Dark factories will be very beneficial to the production power and increase efficiency. At the same time, it will reduce expenses in labor costs and reduce the rate of worker deaths. Although this technique, which will be put into production without manpower, is considered to reduce employment,it will allow the use of technical knowledge and skills in high-skilled jobs and will shift employment to the areas of control and maintenance needed by “continuous production”.
One of the biggest advantages of smart factories is that they eliminate labor costs to a large extent. In addition, all systems from production to distribution work in communication thanks to automation, and any problems that may arise become predictable. Likewise, being able to control all the systems in the factory from a single point means that time losses are prevented. Each stage is constantly kept under control with digital systems. In addition to production, smart factories work by combining many necessary systems such as business management, purchasing, warehouse, shipping, supply, maintenance, energy, software, machine connections. By controlling them from one place;
– All kinds of workflows (algorithms) are provided in order to best meet all the needs that will be needed during the production phase,
– It is ensured that all kinds of software, hardware and system architectures are implemented for the smooth operation of the process,
– The operability of all implemented applications and processes is audited,
– Performance measurements are made,
– Supervision and training of managers such as engineers are organized.
Due to the advantages it provides, the smart factory market receives more and more investments every day. According to the researches, the smart factory sector will grow by 10% every year and reach 391 billion dollars by 2024. Today, many business owners are making the transition to smart factories. It is envisaged that business owners who receive technological assistance in areas such as production, distribution and inventory management will completely switch to smart systems in a few years. 90% of industrial systems currently used are wired and fixed. It is also very costly to bring intelligence to these inflexible systems. In this way, the data cannot be analyzed correctly and a complete intelligence cannot be achieved.
Within the scope of technological and scientific developments on the way to Smart Factories, studies should be carried out on 4 main areas:
1. Electrical, electronics, control, computer and software engineers should work together in the design of sensors, actuators and human/ machine interfaces in enterprises, in the design of smart devices to be used for digital communication with machines. These devices are devices that can implement IoT (Internet of Things), IoS (Internet of Services) type concepts.
2. Computer/software/industrial engineers should construct and implement flexible ERP and MES software that can meet ideal work flow algorithms, and integrate both in-plant and customer and supplier systems.
3. Industrial engineering, who is the user, has a great job to do. As a subbranch in industrial engineering, it is necessary to develop different areas of expertise under the name of “Smart Factory Management”, where complete IT systems can be used while managing production, and the business can be managed in close cooperation with customers and suppliers by using IT-supported management tools.
4. Machinery manufacturers should produce machines in a way that will serve the new flow to be constructed in the enterprise and have smart sensors, controllers, internet and computer facilities that can communicate with the surrounding machines.
What should companies do in digital transformation processes?
With digitalization, many innovations and developments are making a rapid entry into our lives. With the ever-developing technology, business life and especially manufacturing companies are trying to adapt themselves to this digital transformation. Companies that wantto take advantage of digitalization are trying to digitize all processes in areas such as design, production, storage, shipment, sales and marketing. The steps to be taken in this area continue to be digitized every day.
First of all, the concept of digital transformation needs to be understood
Digitalization has entered our lives with an increasing speed, especially in the last century. In the light of developments that have emerged one after the other, an environment where almost every system is increasingly digital has been provided. As digitalization begins to become a fundamental element in life and its natural flow, companies are trying to figure out the details in order to understand, comprehend and adapt themselves to this system. However, at this point, the first step that companies should take is to understand that the concept of digital transformation is not only a structure that concerns the infrastructure and information technologies department. All processes from design to production, from sales to human resources, from communication to logistics are included in digitalization.
They should implement different applications and technologies
Digitalization brings a new order and flow by breaking the standards not only in our private life but also in corporate and business world. In order to keep up with this and to survive in intense competition, it is necessary to benefit from many different applications, infrastructures, systems and strategies. It is inevitable for digital transformation that companies implement many different applications, some of which are free, that they can manage their daily activities and use in the business process.
Internet, online, cloud, artificial intelligence, autonomous…
All companies embarking on a digital transformation journey must first draw up a roadmap, adapt all the company’s workflows and functions, and implement digital infrastructure and platforms in all necessary areas. Digitalization, which used to be expressed only as the renewal of websites
or computers, refers to a structure where almost everything is internetbased, online systems are used, cloud technologies are preferred, operations are carried out on a global basis, artificial intelligence, internet of things and autonomous systems are used. Every sector, company and structure is switching to digital systems in all places where it is needed.
We must be prepared for digital risks
As in the normal flow of life, many risks await SMEs in business life. Be it online or offline platforms, many risks inherent in the natural nature of trading can happen to you at any time. In order to always be prepared for undesirable situations such as business deterioration or stopping, bankruptcy, it is extremely important to take precautions against risks and to create protection against them by calculating their possible situations.
What path is our country following?
In Turkey, important steps are being taken towards Industry 4.0 with many investments and studies made recently. In addition to the support and incentives provided by the public, many companies from the private sector are turning their heads to this field and working on digitizing their production processes. In the “Digital Turkey Roadmap” prepared by the Ministry of Science, Industry and Technology, which includes the steps and solution proposals that Turkey should take on the way to Industry 4.0, a roadmap for the digitalization of the manufacturing industry has also been prepared.
According to this short, medium and long term map, in the first stage (1-2 years), it is aimed to take concrete steps that will accelerate the digital transformation of the manufacturing industry and to create the intellectual and physical infrastructure that will trigger the transformation process. The purpose of the second phase (3-5 years) is to close the gap between us and the countries that are ahead of us in the digitalization journey by further strengthening our competencies and infrastructure. The long-term (6-10 years) vision of the roadmap is that our country gets a larger share of the global value pools of the manufacturing industry and becomes a regional or global leader in selected technology areas.
The roadmap consists of 6 components:
1. Human – Development of educational infrastructure and training of qualified workforce:
It is necessary to increase the level of knowledge and awareness of enterprises in the manufacturing industry about digital technologies, their potential application areas and contributions. At the same time, as the manufacturing industry becomes digital, a workforce with different qualifications and skills will be needed. Starting from primary school, trainings with a weight of application for the development of digital skills at all levels of basic, vocational and higher education and in business life are necessary to train the qualified workforce needed and to develop the competencies of the existing workforce.
2. Technology – Developing technology and innovation capacity:
It is aimed to create a technology infrastructure with strong competencies in digital technology research and with advanced global and national collaborations.
3. Infrastructure – Strengthening the data communication infrastructure:
In order to achieve digital transformation, our country must have a strong communication infrastructure. This infrastructure requires the development of data communication standards and data security in addition to physical investments.
4. Suppliers – Supporting national technology suppliers:
In terms of the sustainability of the digital transformation process, the quality and quantity of businesses that develop digital technology products and services should be increased.
5. Users – Supporting users’ digital transformation:
In order to achieve digital transformation in the manufacturing industry, the digital transformation processes of technology users should be supported.
6. Governance – Strengthening corporate governance:
It is aimed to establish an effective and effective governance structure that will guide the digital transformation process of the manufacturing industryand ensure coordination among stakeholders.
Examples from different geographies
The examples included in the “Digital Turkey Roadmap” prepared by the Ministry of Science, Industry and Technology and which includes the steps and solution proposals to be taken by Turkey on the way to Industry 4.0, show the work done by different countries in this field.
European Union
The Digital Agenda was prepared within the scope of Europe 2020. The strategy of digitization of the industry was developed. A $100 billion grant program was established for R&D and innovation in core technologies.
Germany
Industry 4.0 platform was created. It is planned to establish a national digital agency.
France
The Industrial Strategy of the Future has been prepared. Strategies for critical technologies and sectors were determined. He allocated a loan budget of 10 billion dollars for the Future Industries Program.
England
One of the main elements of the Artificial Intelligence industry strategy is supporting digital transformation with Catapult centers.
The Netherlands
Digital transformation strategy was prepared. Field Lab (digital centers of excellence) network was created.
USA
The “America Makes” program was launched. The National Network of Institutes for Innovation in Manufacturing was established.
China
The Made in China 2025 strategy has been prepared. Digitalization is supported by mega funds. The high-tech incubator created a venture capital fund of 230 billion dollars for 1600 companies.
Japan
With the concept of Society 5.0, the country sees digital transformation as the transformation of the economy and society.
South Korea
Smart Industry Strategy was prepared. It trains an army of designers inthe field of additive manufacturing.