Industry 4.

0
Making your business
more competitive
2

Executive summary

We are at the beginning of the fourth industrial revolution. The most commonly used terms to
describe this development, which is rapidly changing the industrial landscape, are Industry 4.0,
smart manufacturing, the Internet of Things, cyber-physical systems and digital transformation.
The Industry 4.0 concept encompasses the digitalization of the horizontal and vertical value
chain, innovation in products and services and the creation of new business models. The key
business drivers of this transformation include improving customer experience, increasing speed
to market and reducing costs (see figure 1).

To reap the benefits of this revolution, leaders of industrial enterprises have Industry 4.0 at the
top of their agenda. However, implementing an Industry 4.0 production environment will be
an incremental journey over several years that will include modernizing legacy systems. Once
undertaken, the possibilities of applying Industry 4.0 concepts and technology are unlimited.

In this paper, we will answer the questions often asked by our clients:
• What is Industry 4.0?
• Why does Industry 4.0 belong on the C-level agenda?
• What are the business benefits?
• What are the challenges?
• How do businesses implement this approach?

CGI Global 1000 (2016) manufacturing industry insights

• Digital Transformation is accelerating across the value chain
• Reducing costs, improving agility and speed to market are the key business drivers
• IoT, mobile and cloud solutions are essential for the transformation
• IT/Legacy modernization is a key enabler

Industry Trends Business Priorities IT Priorities

Optimize today’s operations-
Digitize and automate
78% Becoming digital organizations 82% cost pressure, agility and 91%
business processes
speed to market
Collaborate across the IT modernization, harmonize
Transformation from product-
71% 67% boundries-digitalization across 74% IT environment, rationalize,
centric to customer-centric
the value chain replace legacy systems

Leverage Internet of Things (IoT),

55% Protecting through cybersecurity 57% Improve the customer experience 63%
mobile, cloud

Deliver product and service

Digitalization extending beyond Leverage data and analytics to
48% 57% innovations with increased 62%
the enterprise derive actionable insight
speed to market
Growth is crucial and BRIC Harness the power of data-
Embrace new IT delivery
45% countries remain key 52% real-time insights and creation 55%
models (e.g. SaaS, PaaS, agile)
despite volatility of new revenue streams

Figure 1: CGI Global 10001 (2016) manufacturing industry insights

1
The annual CGI Global 1000 outlook brings together the findings, insights and CGI’s point of view on the strategic topics that emerged from face-
to-face conversations conducted with business and technology executives in commercial and government organizations. In 2016, CGI consultants
interviewed more than 1,000 executives in 10 industries and 20 countries.
 3

Introduction

Our physical world has become hyper connected and is now rapidly being augmented with a
layer of “smartness.” The fourth industrial revolution—like the ones that came before—is driven
by new technologies. (Figure 2).

Industry 4.0
Integration of digital and
physical systems
∙ Internet of Things
∙ Big data analytics
∙ Robotics and 3D printing

Industry 3.0
Manufacturing with IT to
automate production
∙ Electronics
∙ IT

Industry 2.0
Manufacturing with the help of
electricity (mass production)
∙ Electricity
∙ Conveyor belts
∙ Assembly lines

Industry 1.0
Introduction of mechanical
production facilities
∙ Spinning wheel
∙ Water wheel
∙ Steam engine

1750 1800 1850 1900 1950 2000 2050

Figure 2: Industrial revolutions have always been driven by innovations in technology.

4

Industry 4.0 is enabled by technologies that integrate the digital and real worlds, such as:

• The Internet of Things (IoT): Connecting more and more systems, devices, sensors, assets
and people through networks ranging from wireless, low-power wide-area networks to
wired high-capacity networks
• Mobile solutions: Including smartphones, tablets, wearable sensors and smart glasses
• Cloud computing: Including low-cost processing and data storage solutions
• Cyber-physical systems (CPS): Monitoring and controlling physical processes using sensors,
actuators and processors, based on digital models of the physical world
• Big data analytics and business intelligence: Turning data into actionable insights, which
include early warning algorithms, predictive models, decision support, workflows
and dashboards
• Advanced manufacturing technologies: Including robotics and 3D printing

New technologies have never been more abundant or affordable. At the same time, the
capability to collect, distribute, share and analyze information to make decisions based on real-
time data and predictive analytics, and create new business value has improved considerably.
This is evident from the significant drop in sensor, bandwidth and processing costs in the last 10
years2.

Sensors, bandwidth and processing costs have dropped dramatically in the last decade:

• Sensor prices have dropped to an average of 60 cents.

• The cost of bandwidth has decreased by a factor of nearly 40 times.
• Processing costs have declined almost 60 times.

Today, in the virtual world, new models can be used to simulate and analyze products and
processes from the physical world. In product development, these models can be used for
product optimization and to operate and control the manufacturing process. In business, these
models can even be used to support business decisions.

2
Goldman Sachs. “Internet of Things: Making sense of the next mega trend.” 2014. Accessed November 28, 2016. http://www.goldmansachs.com/
our-thinking/outlook/internet-of-things/iot-report.pdf
 5

Industry 4.0: Why should it be

on the C-level agenda?

The world is evolving more rapidly than ever before. As the adoption of digital technologies
continues to move at a fast pace, organizations are seeking to rapidly transform. Moreover, a
new economic order is emerging, where established manufacturers have to deal with both large
digital organizations and innovative start-ups—both determined to build new revenue models.

New technologies, new products and services and new business models can be disruptive. In
this scenario, adopting Industry 4.0 principles becomes a necessity, and tomorrow’s leaders
need to be prepared to embrace a different corporate structure. In this new economic order,
Industry 4.0 will transform businesses in several ways:

• Corporate strategy. Industry 4.0 solutions will change the way companies operate. They
will impact the product and service portfolio of companies. Today, smart products and
services need to be developed, but tomorrow new business models will become necessary.
In addition, start-ups with disruptive value propositions will enter the market. Under these
conditions, implementing Industry 4.0 will require C-level commitment. Companies will need
to understand the impact of digital transformation throughout their business.
6

• Supply chain management, operations management and product life cycle

management. Digitalization is already making it easier for companies to collaborate. Cloud-
based solutions are enabling companies to share data among customers, suppliers and
other supply chain partners. However, a connected demand-driven supply chain cannot
be achieved if departments and companies operate in silos. Integration of operations
technology (OT) and information technology (IT) is required to connect process control,
operations management and business planning. Organizations will also need digital product
models for end-to-end product life cycle management.

• Investment. Industry 4.0 will have a big impact on the IT landscape. Digitalization will
move from being an innovative trend to becoming a core competency3. The insights
from the 2016 CGI Global 1000 outlook4 reveal that manufacturing organizations want to
decrease the cost of running legacy systems and processes, and increase investments in
digital transformation (see figure 1). However, they are struggling to change the mix to fund
transformation, as they need to run their current business, while transforming to Industry
4.0. In their efforts to accelerate business transformation, manufacturers are accelerating
automation and digitization. While in 2015, only half the manufacturing executives
interviewed cited digitalization and automation of business processes as a top IT priority, in
2016 more than 90% are investing in these areas in order to remain competitive and reduce
operational costs (see figure 3). In this environment, the board of directors will need to make
strategic investment decisions, align the IT investment portfolio with business priorities and
maximize return on investment. In addition, CIOs will have to lead businesses in applying
technology to enable innovation and advance business objectives.

3
“Keeping up versus stepping up.” CGI.com. Accessed November 28, 2016. https://www.cgi.com/sites/default/files/white-papers/keeping-up-
versus-stepping-up_white-paper.pdf
4 In 2016 as part of CGI Global 1000 outlook, CGI conducted 87 in-person interviews with business and IT executives in manufacturing
organizations across 13 countries to gain insights on top industry trends and their business and IT priorities and plans.
 7

Digitize and automate business processes -

Reduce operational costs and improve
customer experience

Drive IT modernization

Leverage Internet of Things, mobile, cloud 2015

2016
Leverage data and analytics to derive
actionable insight

Embrace new IT delivery models (e.g) SaaS,

PaaS, agile) - Reduce costs and increase agility

0 10 20 30 40 50 60 70 80 90 100

Figure 3: CGI Global 1000 (2016) - Manufacturing IT priorities

8

Industry 4.0: What are the

business benefits?
The possibilities of applying Industry 4.0
technology are unlimited.

A digitally-integrated and intelligent supply chain enables an unprecedented level of collaboration

and real-time visibility across the supply chain to help address rising customer expectations

Raw Material
Producer
Supplier Transport Manufacturer Distributor Retail Consumer

Figure 4: Imagine the real-time connected supply chain

Imagine a real-time connected supply chain. What if all the participants in the supply chain
shared data from their production sites, vehicles, warehouses and databases in real time?
What if you used real-time points of sale and inventory data to understand the state of your
business? Would you be better equipped to accommodate critical orders and meet customer
expectations with faster, more accurate shipping and handling?

Imagine connected vehicles, containers and pallets. What if your company tracked and
controlled the condition and location of your products throughout the supply chain? Would this
help your company improve inventory management and product quality? Would serialization
help your company deal with fraud and counterfeit products?

Imagine connected smart production equipment. What if equipment settings were self-adjusted
based on materials used, products being made and other ambient conditions? Is your company
able to customize mass-produced products based on the needs of an individual customer?
What if equipment could be monitored remotely and malfunctions predicted accurately?

Imagine connected mobile and wearable devices. What additional functionalities and services
would your company deliver to customers? How would you improve worker safety?

Whatever your business, what if a fluid digital continuum could connect your departments,
customers, suppliers, partners, production equipment and products throughout your product
and services life cycles?
 9

A digitally-integrated and intelligent value chain offers almost limitless possibilities. Industry 4.0
solutions improve operations efficiency, productivity, product quality, inventory management,
asset utilization, time to market, agility, workplace safety and environmental sustainability.

Figure 5 identifies the main activities that are enabled by Industry 4.0 technologies.

Marketing Inbound Outbound Maintenance

Planning Development & Sales Logistics Production Logistics & Services

Forecasting Product Lifecycle Customer Track and Operational Distribution Maintenance, Repair
methods Mngt (PLM) intelligence Trace products intelligence planning and Overhaul (MRO)

Collaborative Connected Smart Advanced Inventory Enterprise Asset

Promotions
work products containers process control management Management (EAM)

Demand Collaborative Digital Manufacturing Warehouse

Serialization Field services
management engineering marketing Execution Systems management

Integrated Remote eCommerce Just-in-time (JIT) Smart tools and Transport Predictive
enterprise mngt monitoring solutions logistics machines management maintenance

Safety stock Remote Point-of-sale Supplier Energy Track and Mobile worforce
optimization software update (POS) analytics collaboration management Trace products management

Collaborative User consumer Inventory Predictive Augmented

engineering experience management maintenance reality

3D product Secure payment Quality Condition

models systems management monitoring

Process Tracking Remote

Servitization
stimulation genealogy maintenance

Smart packaging

Figure 5: Industry 4.0 solutions by business function

Today, the most promising Industry 4.0 solutions are energy management and predictive
maintenance, especially in combination with manufacturing execution systems (MES). This was
visible at Hannover Messe, in April 2016, where condition monitoring, predictive maintenance
and energy management were the most commonly shown use cases.
10

Predictive maintenance
Using sensors to determine when equipment needs to
be serviced can prevent breakdowns and reduce routine
maintenance costs
With in-built sensors connected to the Internet, it is possible to monitor production
equipment remotely and in real time. This enables predictive maintenance, where
analytical models can be applied to predict future areas of concern. In this case,
recommendations can be sent to operations, maintenance and IT departments to
address a breakdown, even before it occurs. By doing so, operating costs and capital
costs can be reduced by facilitating proactive servicing and repair of equipment, thereby
improving capacity utilization and productivity.

Together with Microsoft, CGI has developed an elevator maintenance solution for one
of the world’s leading elevator manufacturers, using the latest Internet of Things (IoT)
technology. The company, which maintains more than 1.2 million elevators around
the world, wanted to transition to a more proactive, predictive maintenance approach
driven by real-time data. The solution extracts data from smart sensors on the elevator,
generates valuable insight using analytics, and makes the information available to
supervisors and service technicians via cloud-based dashboards. The system was
implemented for a number of the company’s elevators and has resulted in reducing
elevator downtime and improving resource planning, cost forecasting and maintenance
scheduling.

In this way, equipment manufacturers can use IoT technology to change their business
model to a service model, provide ongoing maintenance under contract and guarantee a
defined uptime for equipment. IoT technology enables real-time monitoring and remote
service. In addition, performance data can be gathered to improve the design and reliability
of the equipment, thereby reducing warranty costs. Once equipment is interconnected and
managed through IoT, it is possible to improve asset utilization significantly.

According to research by McKinsey & Company5, predictive maintenance using IoT can
reduce maintenance costs of factory equipment by 10–40% and bring down equipment
downtime by up to 50%.

5
James Manyika, Michael Chui, Peter Bisson, Jonathan Woetzel, Richard Dobbs, Jacques Bughin, and Dan Aharon. “ The Internet of Things:
Mapping the value beyond the hype.” McKinsey & Company. June 2015. Accessed January 31, 2017. http://www.mckinsey.com/business-
functions/digital-mckinsey/our-insights/the-internet-of-things-the-value-of-digitizing-the-physical-world
 11

Energy management
Managing energy consumption results in greener
operations, lower energy costs, lesser unplanned
downtime and more consistent quality
Manufacturers are increasingly pursuing a resource efficient and sustainable approach
due to several economic, social and governmental pressures. In energy-intensive
industries, energy costs form a significant part of the operation costs. In this scenario,
the use of IoT and predictive analytics has an important role, as these technologies can
reduce energy consumption and operating costs significantly.

In manufacturing organizations, metering does not reveal how energy is distributed

across buildings, processes and equipment. Therefore, the first step towards developing
a systematic approach to energy management and improving a company’s competitive
position lies in the increased visibility of energy consumption patterns.

CGI has worked extensively in this area, as we have built energy monitoring systems
for clients in the chemical and food industries. Our insight into the use of energy saves
millions of dollars in operating costs. For instance, CGI’s energy monitoring system
(EMS) for a global manufacturer of confectionery, pet food and other food products
has been deployed in multiple factories—reporting on energy consumed by end-users,
improving their energy efficiency and reducing energy consumption.

In our experience, energy consumption in a plant can be easily monitored through

sensors in a facility and production equipment. Monitoring deviations from regular
energy consumption can help to detect failing equipment. In addition, manufacturing
execution systems (MES) capture relevant data, such as equipment settings, shifts
and process parameters, providing insight into how energy is used in operations.
Further, predictive analytics also provides manufacturers with insights that help in the
implementation of energy programs.

According to research by McKinsey & Company 6 , PWC7 and Roland Berger 8 , energy
management using IoT can reduce factory energy costs by 10–30%.

6
Ibid
7 Dr. Reinhard Geissbauer, Simon Kuge, Stefan Schrauf, Volkmar Koch. “Industry 4.0: Opportunities and Challenges of the Industrial Internet.”
Strategy&. Accessed November 28, 2016. http://www.strategyand.pwc.com/reports/industry-4-0
8 Marc Winterhoff. Stephan Keese, Christian Boehler, Christopher Hoyes. “Digital factories: The renaissance of the U.S. automotive industry”. Roland Berger.
Accessed November 28, 2016. https://www.rolandberger.com/publications/publication_pdf/roland_berger_tab_digital_factories_20160217.pdf.
12

Other areas of interest are supply chain management and inventory management. Industry 4.0
solutions can offer manufacturers a comprehensive view of the production process and provide
real-time controls that facilitate an uninterrupted flow of finished products and avoid defects.
Additional sensors can also be installed in plants to monitor process conditions with greater
granularity, while models can be used to predict process capability and product quality. This
helps organizations to monitor the end-to-end manufacturing process, address bottlenecks,
reduce waste and energy costs, and remove operator intervention.

IoT can also improve inventory management by using weight or height detection sensors to
enable condition-based automatic reordering, depending on actual stock quantities, instead of
replenishment estimates. Furthermore, remote monitoring and sensing of toxic gas, oxygen and
ozone levels inside plants can dramatically increase workplace safety9.

Before starting with a new project, most companies look for the business case. Although
quantifying business benefits for Industry 4.0 in general is not an exact science, one can look
to recent research from multiple companies (The Smart Manufacturing Leadership Coalition10,
McKinsey & Company11, PWC12 and Roland Berger13) to derive expected benefits, including:

manufacturing costs

logistics costs

quality costs

labor costs

energy costs

water usage

factory inventory carrying costs

productivity

overall operating efficiency

resource efficiency Reduce by (%)

-50 -40 -30 -20 -10 0 10 20 30 40 50 Increase by (%)

Figure 6: Improve operating efficiency

9
James Manyika, Michael Chui, Peter Bisson, Jonathan Woetzel, Richard Dobbs, Jacques Bughin, and Dan Aharon. “ The Internet of Things: Mapping
the value beyond the hype.” McKinsey & Company. June 2015. Accessed January 31, 2017. http://www.mckinsey.com/business-functions/digital-
mckinsey/our-insights/the-internet-of-things-the-value-of-digitizing-the-physical-world
10 “
Economic Benefit”. Smart Manufacturing Leadership Coalition. Accessed November 28, 2016. https://smartmanufacturingcoalition.org/economic-
benefit
11 James Manyika, Michael Chui, Peter Bisson, Jonathan Woetzel, Richard Dobbs, Jacques Bughin, and Dan Aharon. “Internet of things: Mapping the
value beyond the hype”. McKinsey & Company. June 2015. Accessed November 28, 2016. http://www.mckinsey.com/business-functions/digital-
mckinsey/our-insights/the-internet-of-things-the-value-of-digitizing-the-physical-world
12 Dr. Reinhard Geissbauer, Simon Kuge, Stefan Schrauf, Volkmar Koch. “Industry 4.0: Opportunities and Challenges of the Industrial Internet.” Strategy &.
Accessed November 28, 2016. http://www.strategyand.pwc.com/reports/industry-4-0
13 Marc Winterhoff. Stephan Keese, Christian Boehler, Christopher Hoyes. “Digital factories: The renaissance of the U.S. automotive industry”. Roland
Berger. Accessed November 28, 2016. https://www.rolandberger.com/publications/publication_pdf/roland_berger_tab_digital_factories_20160217.pdf.
 13

maintenance costs

unplanned downtime

equipment life time

equipment capital investment Reduce by (%)

-50 -40 -30 -20 -10 0 10 20 30 40 50 Increase by (%)

Figure 7: Improve asset management

safety incidents / insurance costs Reduce by (%)

Increase by (%)
-50 -40 -30 -20 -10 0 10 20 30 40 50

Figure 8: Improve safety

retailer inventory carrying costs

container utilization

error rates in order picking activities

number of lost packages Reduce by (%)

-50 -40 -30 -20 -10 0 10 20 30 40 50 Increase by (%)

Figure 9: Improve supply chain management

revenue in new products and services

Reduce by (%)

-50 -40 -30 -20 -10 0 10 20 30 40 50 Increase by (%)

Figure 10: Improve revenue

reduce time to market

Reduce by
-50 -40 -30 -20 -10 0 10 20 30 40 50 number of times

Figure 11: Reduce time to market

Note: The figures in the above diagrams are only indicative and may vary among industries and companies.
14

Industry 4.0: What are the

challenges?

Industry 4.0 comes with challenges. Today, manufacturers deal with huge quantities of
information, both structured and unstructured, which reside in databases that are not always
properly connected. To create business value and meet customer expectations in terms of
innovation, personalization and speed to market, it is necessary to connect these silos and
enable a single, unbroken collection of data that is woven throughout the supply chain. In order
to achieve this, the following areas need to be addressed:

• Awareness: Many manufacturers are still unaware of the possibilities that Industry 4.0
technologies can offer14 and company-specific business cases do not demonstrate this suitably.

• People: Introducing new business models, business processes, and connected products
and services will transform the way employees perform everyday tasks. In order to deploy
Industry 4.0 solutions, companies need new people and skills. Certain jobs like those of
industrial workers will change or might even become redundant. Warehouse workers,
for instance, are expected to be replaced by autonomous robots. New roles, such as
“robot coordinator” and “data scientist”, have been created, while routine and physically
demanding jobs will disappear. Data scientists, for instance, collect and analyze data and
apply their insights to improve manufacturing processes and products. Robot coordinators
oversee robots on the shop floor, responding to malfunctions and carrying out maintenance
tasks. Industrial workers have to adapt to new roles and work environments. Today,
operators already monitor multiple machines and processes simultaneously, while service
technicians are assisted by augmented-reality technology and remote guidance from
experts offsite. Jobs will require more and more flexibility, IT competency, knowledge of
manufacturing and analytical skills. In this scenario, where resistance to change is the main
barrier, people will need to be motivated and trained to deliver new products, services and
business processes.

• Cybersecurity: With digital factories and a digitally-connected value chain, traditional IT

security is not enough to protect the business. To overlook this reality is to compromise the
stability and security of the company. As companies innovate, the “attack surface area” or
the enterprise area that is vulnerable, gets bigger. The challenge lies in understanding the
potential cyber risk that innovation brings. A single plant shut down can cause production
losses of millions of dollars each day. Therefore, cybersecurity risks must be mitigated.
Industrial IoT devices must be highly secure by design, and securely integrated into existing
automation and information system architectures. Since breaches are inevitable, detection

14
Mathew Littlefield. “Smart Connected Operations: Capturing the Business Value of the Industrial IoT.” LNS Research. 2015. Accessed November
28, 2016. http://www.lnsresearch.com/research-library/research-articles/-ebook-smart-connected-operations-capturing-the-business-value-of-
the-industrial-iot
 15

and response mechanisms have to be in place in the industrial control systems (ICS) area as
well. This will build a necessary level of resilience for the company. In these circumstances,
securing industrial control systems and ensuring cybersecurity cannot be understated. This
can also help manufacturing organizations differentiate themselves from the competition.

• Investments: In order to implement Industry 4.0 solutions, considerable investments are

required to create a robust and secure network infrastructure and upgrade or replace legacy
systems. To justify these investments, benefits have to be unequivocally and reliably quantified.

• Collaboration: Today, no single vendor can deliver all the capabilities needed to implement
Industry 4.0 solutions, as they are based on multiple technologies and devices that run on
different networks. The delivery of Industry 4.0 solutions will be facilitated by an ecosystem
of IT vendors, OT vendors, system integrators and emerging IoT startups. The critical
success factor is close collaboration between the business, IT and OT.

• Standardization: Existing manufacturing standards are insufficient to fully enable Industry

4.0 and new technical, architectural and business standards are needed. As an increasing
number of devices and systems that use proprietary communication protocols enter
the market, data silos are formed, creating a complex network of connections between
isolated data sources. Although multiple standardization bodies and industry consortia
have published reference architectures and standards, there are no universal standards.
This makes it tough for organizations to eliminate data silos. In fact, for years to come, the
Industry 4.0 ecosystem will consist of multiple reference architectures, standards
and protocols.

• IT modernization: Currently, industrial automation system deployments are a collection

of proprietary technologies and networks. In the future, we will need to connect business
planning and logistics solutions, manufacturing operations management solutions and
industrial control systems, such as supervisory control and data acquisition (SCADA),
distributed control system (DCS), programmable logic controller (PLC) and human-machine
interface (HMI). Processes will not be controlled by a standard programmable logic
controller (PLC) anymore, but by a service-oriented, decentralized control system consisting
of distributed microcontrollers that communicate using Internet standards. Already, hybrid
IT environments combining cloud and traditional IT delivery models are on the rise, as
cloud computing continues to emerge as a key enabler of both digital transformation and
operational efficiency.
16

Industry 4.0: How will it impact

the IT and OT?

Creating an Industry 4.0 production environment will be an incremental journey over many
years. For decades, the ISA 95 reference architecture has been used to describe the systems
and processes used across the enterprise. We expect that Industry 4.0 will change the ISA 95
reference model. Devices, process control systems, manufacturing execution systems and ERP
systems will also be connected to IoT platforms (see figure 12).

4. Business
3. Manufacturing
Planning and
Operations
Logistics
Management
Plant production Production,
scheduling, business maintenance, quality,
management, etc. inventory

Industry 4.0
Smart Solutions
5. Supply
• Internet of Things 2. Process Control
Chain Optimization
– Mobile Devices
Production and materials – Wireless Sensor Networks
Discrete, batch, and
planning continuous control
– Cloud Computing
• Big Data Analytics
• Cybersecurity

External 0. Production 1. Sensors,

systems Equipment and Intrumentation,
Materials Data Collection
Physical production Sensing and
process manipulating devices

Figure 12: Enabling the digital enterprise by connecting legacy systems and leveraging Industry 4.0 solutions
 17

Modernizing existing unconnected devices and systems will be critical to become more
competitive.

Industry 4.0 enables shop floor (OT) and top floor (IT) integration by:
• Modernizing existing plants and assets by connecting existing IT and OT systems, sensors,
devices, assets, products and materials with an IoT platform
• Creating new Industry 4.0 solutions that integrate data, people, workflows and legacy
systems with solutions and services delivered via the cloud
18

Industry 4.0: How to implement

this approach?

Developing successful Industry 4.0 solutions can be a complex task. Mikado, a pick-up sticks
game is a good metaphor to illustrate the complexity involved and the vision required to
implement Industry 4.0 solutions. In the game, to change the position of one stick, you need
insight into the impact that it will have on the movement of the other sticks.

Services Products

People Processes

Data Organization

Infrastructure Applications

Figure 13: Mikado—what elements of your operating model will change?

Implementing Industry 4.0 technology successfully is similar. It requires a structured, holistic

approach that is focused on increasing business value and reducing business risks. CGI’s
Digital Transformation Delivery Framework (see figure 14) offers a structured approach to
manage interrelated changes in the operating model of an enterprise (products and services,
organization, people, processes, applications and infrastructure). The framework adopts the
following approach:

• First, a clear vision is needed on how Industry 4.0 impacts your business.
• Based on that vision, plans are made to shape future operations.
• Based on those plans, current operations are changed.
• Finally, the future mode of operation is delivered. This includes an effective approach for
program management, stakeholder engagement, and benefits and risk management, in
order to control the transformation and its outcome.
 19

N SH
IO Organization
S

AP
VI

E
Products Processes
and Services

Value
Technology People
DE

Data
E
LI

ER
N

A
V

CH

Figure 14: CGI’s Digital Transformation Delivery Framework

The next step depends on your Industry 4.0 maturity level

The Industry 4.0 journey starts with the availability of data. Whether you are building new
facilities or refurbishing an existing plant, production equipment, systems and sensors can
generate large amounts of data on every aspect of the operation. This data has to be collected,
aggregated, and analyzed to unlock its business value for Industry 4.0 solutions.

Deriving value from data largely depends on an organization’s capability to collect, manage and
analyze data. Today, while sensors and production systems can generate massive volumes
of data, making sense of this data flood requires strong data management, storage and high-
performance data analytics capabilities.

The roadmap for implementing Industry 4.0 depends on the digital capabilities of an
organization. In our Industry 4.0 maturity model, we distinguish five maturity levels. These
characteristics are shown in figure 15 and described below.
20

Leadership

Create awareness Build proof Define/implement Define/implement Create new

and discover the of concepts an Industry 4.0 an Industry 4.0 (disruptive) products,
benefits Collaborate with IT strategy for the strategy for the services and
and OT vendors enterprise value chain business models

Data silos Share data Share data across Share data Share data across
between the enterprise between the value chain
Data

departments Implement Master companies Implement data

analyze, and obtain Data Management Implement clear quality as KPI
new insights data ownership
Technology

Technology silos Connected devices IT modernization Apply secure Xaas

Descriptive and data sources Application open standards Prescriptive analytics
analysis Diagnostic analytics integration Predictive analytics
IoT platform
Security

Basic network Ad hoc application Enterprise-wide Identity-aware Adaptive and

protection and infrastructure application and information automated security
protection infrastructure protection control
protection

Ignoring Exploring Standardizing Adopting Adapting

Figure 15: Industry 4.0 characteristics based on maturity level

1. Ignoring: Business units and departments act as standalone entities, formulating their own
strategies and work plans. They have their own systems and data silos that run parallel to
each other. The focus is on the execution of tasks of the organizational unit. Data collection
and analytics are used for reporting and answering the question “what happened?”. There is
basic network protection, as production equipment and systems are not connected to the
Internet. The ability to move to the next maturity level depends on the awareness, interests,
knowledge and capabilities of individuals.

2. Exploring: Business units and departments start to collaborate—sharing data, integrating

applications and experimenting with new Industry 4.0 technologies. Data collection and
analytics is used for understanding and answering the question “why did it happen?”. The
integration of OT and IT IoT platforms are used to collect and analyze data. The first projects
are initiated by Industry 4.0 evangelists. Applications and infrastructure are provided with ad
hoc cybersecurity safeguards.

3. Standardizing: Business units and functions collaborate across the enterprise. In addition,
the organization defines an Industry 4.0 enterprise strategy, reference architecture, and
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standards for data and end-to-end process automation. Production equipment and systems
are connected to IoT platforms. Data collection and analytics are used for prediction,
answering the question “what is likely to happen?”. There is enterprise-wide application and
infrastructure protection.

4. Adopting: This level is characterized by collaboration between enterprises across the

business ecosystem. The organization defines an Industry 4.0 strategy and reference
architecture for the business ecosystem. Data is shared in real time across company
boundaries. As a result, real-time data collection and analytics are used in operations,
answering the question “what is happening?”. Applications built on IoT platforms provide
additional services and predictive models are used to support decision making. There is
identity-aware information protection.

5. Adapting: These companies are at the highest level of maturity and lead the business
ecosystem. They introduce new and disruptive products, services and business models,
which are based on automation of the value chain. Real-time data collection and analytics
are used in operations to answer the question “how can we make it happen?”. Prescriptive
models are used to simulate and optimize the business. There is adaptive and automated
security control.

The first step in the Industry 4.0 journey is making executives and business owners aware of
the impact that Industry 4.0 can have on their business. They have to be aware of the benefits
that Industry 4.0 technology can offer and understand the use cases, value of data and the
importance of cybersecurity.

The next step is to identify, prioritize and pilot Industry 4.0 solutions for the most promising use
cases that can help reduce operating costs. Reduction of operating costs makes your business
more competitive and generates resources for other Industry 4.0 solutions. For each use case,
proof of concepts must be built to explore suitability for the organization and gain experience.
In order to obtain new insights and generate business value, devices and systems have to be
connected to an IoT platform, and data has to be collected and analyzed. In this context, good
collaboration with multiple vendors is essential.

Once you have explored and implemented several Industry 4.0 solutions, you will understand
that defining and implementing an Industry 4.0 strategy is necessary to align different business
functions. A key element of the Industry 4.0 strategy is IT modernization to remove any
roadblocks. Another important activity is to define Industry 4.0 reference architecture.

The next level will be to share data across companies and make decisions regarding important
activities such as data ownership and metadata management. It is also important to build
predictive models to optimize business processes. Eventually, data quality key performance
indicators are implemented across the supply chain and the business is optimized based on
prescriptive models. New and disruptive, products, services and business models are created.
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Conclusion

Industry 4.0 will change the entire manufacturing system, from the architecture and
organizational structure to products, services and business models. The development and
deployment of these solutions will be incremental and part of a long-term trend, but the
opportunity is already here today.

Companies that fail to educate themselves on these new technologies and invest in
pilot projects will lose their competitive advantage and miss the opportunity to lead the
transformation that is currently sweeping across the manufacturing industry.

If you have not yet begun on this journey, you must start today.

About the authors

This white paper has been created by a team of senior experts at CGI who have more than 25
years of experience in the manufacturing industry, advising leading manufacturing organizations
on their transformation and supporting complex transformations. In this paper, they share their
deep understanding of manufacturing organizations’ processes as well as their expertise in the
latest technologies, software and methodologies for the digital century.
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About CGI in Manufacturing

CGI is the partner and expert of choice for manufacturers in a wide range of sectors, including
automotive, aerospace, high tech, mining, metals, pulp and paper, and chemicals. Our 2,800
supply chain experts help clients modernize legacy systems, optimize operations and digitize
processes by driving cross-functional collaboration and data continuity across traditional
silos and throughout the ecosystem. Our client-inspired business solutions enable them to
drive down costs and increase productivity and agility to digitally transform and grow. As our
manufacturing clients embark on their journey to Industry 4.0, we have the talent, scale and
in-depth industry expertise to help them transform from product-centric to customer-centric
businesses, bringing forth innovative strategies and technologies to enable their transformation
end-to-end.

For more information, please visit www.cgi.com/manufacturing

Founded in 1976, CGI is one of the world’s largest IT and business
process services providers. We help clients transform into customer-
centric digital enterprises end to end through high-end business and
IT consulting, systems integration and transformational outsourcing
services combined with a unique client proximity and best-fit global
delivery model.

Visit cgi.com or contact us at [email protected] for more information.

© 2017 CGI GROUP INC.

All rights reserved. This document is protected by international copyright law and may not be
reprinted, reproduced, copied or utilised in whole or in part by any means including electronic,
mechanical, or other means without the prior written consent of CGI. The project referenced in
this brochure was delivered by CGI. Whilst reasonable care has been taken by CGI to ensure
the information contained herein is reasonably accurate, CGI shall not, under any circumstances
be liable for any loss or damage (direct or consequential) suffered by any party as a result of the
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