Introduction To I.R 4.0 en
Introduction To I.R 4.0 en
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Introduction to IR 4.0 i
Table of Contents
Chapter Page
CHAPTER 1 INTRODUCTION TO INDUSTRIAL REVOLUTION 4.0 (IR4.0) 1
1.1 What Is Industrial Revolution 4.0? 1
1.2 History: From Industry 1.0 to Industry 4.0 2
1.3 The Nine Pillars of Industry 4.0 4
1.4 Benefit of Digitization 9
- CHAPTER 1 -
INTRODUCTION TO INDUSTRIAL REVOLUTION 4.0 (IR 4.0)
Objectives:
• To understand more about Industrial Revolution 4.0
• To learn more about the history of Industrial Revolution
• To learn more about Nine Pillars of Industry 4.0
• To learn more about benefit of Digitization
Industry 4.0 refers to a new phase in the Industrial Revolution that focuses heavily on
interconnectivity, automation, machine learning, and real-time data. Industry 4.0, which
encompasses IIoT and smart manufacturing, marries physical production and operations with
smart digital technology, machine learning, and big data to create a more holistic and better-
connected ecosystem for companies that focus on manufacturing and supply chain
management.
While every company and organization operating today is different, they all face a common
challenge—the need for connectedness and access to real-time insights across processes,
partners, products, and people. Industry 4.0 isn’t just about investing in new technology and
tools to improve manufacturing efficiency—it’s about revolutionizing the way your entire
business operates and grows.
The world of manufacturing is changing. To survive and thrive now, you have to be willing to
invest in Industry 4.0. This resource will help you get started.
Introduction to IR 4.0 2
When these enablers come together, Industry 4.0 has the potential to deliver some incredible
advances in factory environments. Examples include machines which can predict failures and
trigger maintenance processes autonomously or self-organized logistics which react to
unexpected changes in production.
And it has the power to change the way that people work. Industry 4.0 can pull individuals into
smarter networks, with the potential of more efficient working. The digitalization of the
manufacturing environment allows for more flexible methods of getting the right information
to the right person at the right time. The increasing use of digital devices inside factories and
out in the field means maintenance professionals can be provided with equipment
documentation and service history in a timelier manner, and at the point of use. Maintenance
professionals want to be solving problems, not wasting time trying to source the technical
information that they need.
The Boston Consulting Group has identified Industry 4.0’s nine technological pillars:
Long used to tackle complex tasks, robots provide an ever-wider range of services and are
becoming more autonomous, flexible, and cooperative. They will interact with one another
and work safely with humans (the term “cobotics” is used to describe robots helping operators
perform their tasks). Eventually, they will be able to learn from humans.
1.3.2 Simulation
Today, information systems are not fully integrated. Companies are rarely connected with their
suppliers and customers. Engineering design departments are seldom linked directly to
production within its own organization. But with Industry 4.0, the entire organization will be
interconnected, and companies will be connected with one another.
Few machines are currently fitted with sensors and interconnected. With the Industrial Internet
of Things, an ever-greater number of products will incorporate intelligence and be connected
using standard protocols. This will decentralize analytics and decision-making, enabling real-
time responses.
Introduction to IR 4.0 7
1.3.5 Cybersecurity
The days of closed, unconnected operational management systems are over. Connectivity
and communication protocols are becoming the norm. Protecting information systems and
manufacturing lines from cybercrime threats is becoming a critical issue. Sophisticated identity
and machine access management systems will be used to provide secure, reliable
communications.
Companies have just begun to adopt 3D printing for prototyping and unit production. With
Industry 4.0, these technologies will be chosen for their very high performance in producing
small batches of customized products. Decentralized systems will reduce transportation and
inventory management costs.
Introduction to IR 4.0 8
Augmented-reality tools are still in their infancy, but they are paving the way for new services.
For example, they will provide operators with the real-time information they need for faster
decision-making and for improving work processes.
There are still massive sets of untapped data in the industrial world. Their analysis will optimize
production quality, save energy, and improve services. Here as well, the goal is to allow real-
time decision-making.
Introduction to IR 4.0 9
Consumers digitize much faster than businesses. That is why a digitally transformed organization
obtains more benefits than companies that continue with the traditional business model.
Therefore, it is essential to know the current situation your company is in and, thus, approach
the process in the most effective and efficient way possible.
• Improved productivity
Thanks to process automation, employees carry out their tasks in a much more agile,
autonomous and efficient way. Also, they can monitor the status of their projects in real
time and manage time appropriately.
- CHAPTER 2 -
PILLAR 1 – SUPPLY CHAIN
Objectives:
• To understand more about Supply Chain Management (SCM)
• To learn more about key component of current value chain
• To learn more about benefit of SCM
• To learn more about value chain analysis
"Supply Chain 4.0 - the application of the Internet of Things, the use of advanced robotics, and
the application of advanced analytics of big data in supply chain management: place
sensors in everything, create networks everywhere, automate anything, and analyse
everything to significantly improve performance and customer satisfaction".
Over the last thirty years, logistics has undergone a tremendous change: from a purely
operational function that reported to sales or manufacturing and focused on ensuring the
supply of production lines and the delivery to customers, to an independent supply chain
management function that in some companies is already being led by a CSO - the Chief
Supply Chain Officer. The focus of the supply chain management function has shifted to
advanced planning processes, such as analytical demand planning or integrated S&OP,
which have become established business processes in many companies, while operational
logistics has often been outsourced to third-party LSPs. The supply chain function ensures
integrated operations from customers to suppliers.
Introduction to IR 4.0 12
Several mega trends have a heavy influence on supply chain management: there is a
continuing growth of the rural areas worldwide, with wealth shifting into regions that have not
been served before. Pressure to reduce carbon emissions as well as regulations of traffic for
socioeconomic reasons add to the challenges that logistics are facing. But changing
demographics also lead to reduced labour availability as well as increasing ergonomic
requirements that arise as the workforce age increases.
At the same time customer expectations are growing: the online trend of the last years has led
to increasing service expectations combined with a much stronger granularization of orders.
There is also a very definite trend towards further individualization and customization that drives
the strong growth of and constant changes in the SKU portfolio. The online-enabled
transparency and easy access to a multitude of options regarding where to shop and what to
buy drives the competition of supply chains.
Introduction to IR 4.0 13
To build on these trends and cope with the changed requirements, supply chains need to
become much faster, more granular, and much more precise.
• Faster
New approaches of product distribution reduce the delivery time of high runners to few
hours. The basis for these services is built by advanced forecasting approaches, e.g.,
predictive analytics of internal (e.g., demand) and external (e.g., market trends,
weather, school vacation, construction indices) data as well as machine status data
for spare-parts demand, and provides a much more precise forecast of customer
demand. Forecasts are not carried out on a monthly basis, but weekly, and for the very
fast-moving products even every day. In the future we will see "predictive shipping," for
which Amazon holds a patent - products are shipped before the customer places an
order. The customer order is later on matched with a shipment that is already in the
logistics network (being transported towards the customer region) and the shipment is
rerouted to the exact customer destination.
Introduction to IR 4.0 14
• More flexible
Ad hoc and real-time planning allows a flexible reaction to changing demand or
supply situations. Planning cycles and frozen periods are minimized and planning
becomes a continuous process that is able to react dynamically to changing
requirements or constraints (e.g., real-time production capacity feedback from
machines). Once the products are sent, increased flexibility in the delivery processes
allows customers to reroute shipments to the most convenient destination.
New business models, such as Supply Chain as a Service for supply chain planning functions or
transport management, increase the flexibility in the supply chain organization. Supply chain
can be bought as a service and paid for on a by-usage basis instead of having the resources
and capabilities in-house. The specialization and focus of service providers allow them to
create economies of scale as well as economies of scope and also attractive outsourcing
opportunities.
The value chain framework is made up of five primary activities -- inbound operations,
operations, outbound logistics, marketing and sales, service -- and four secondary activities --
procurement and purchasing, human resource management, technological development
and company infrastructure.
A value chain analysis is when a business identifies its primary and secondary activities and sub
activities, and evaluates the efficiency of each point. A value chain analysis can reveal
linkages, dependencies and other patterns in the value chain.
Introduction to IR 4.0 15
The value chain concept was first described in 1985 by Harvard Business School professor
Michael Porter, in his book Competitive Advantage: Creating and Sustaining Superior
Performance.
Introduction to IR 4.0 16
Analysing these value chain activities, sub activities and the relationships between them helps
organizations understand them as a system of interrelated functions. Then, organizations can
individually analyse each to assess whether the output of each activity or sub activity can be
improved -- relative to the cost, time and effort they require.
When an organization applies the value chain concept to its own activities, it is called a value
chain analysis.
Primary Activities
Primary activities contribute to a product or service's physical creation, sale, maintenance and
support. These activities include the following:
• Inbound operations. The internal handling and management of resources coming from
outside sources -- such as external vendors and other supply chain sources. These
outside resources flowing in are called "inputs" and may include raw materials.
• Operations. Activities and processes that transform inputs into "outputs" -- the product
or service being sold by the business that flow out to customers. These "outputs" are the
core products that can be sold for a higher price than the cost of materials and
production to create a profit.
• Outbound logistics. The delivery of outputs to customers. Processes involve systems for
storage, collection and distribution to customers. This includes managing a company's
internal systems and external systems from customer organizations.
• Marketing and sales. Activities such as advertising and brand-building, which seek to
increase visibility, reach a marketing audience and communicate why a consumer
should purchase a product or service.
• Service. Activities such as customer service and product support, which reinforce a
long-term relationship with the customers who have purchased a product or service.
As management issues and inefficiencies are relatively easy to identify here, well-managed
primary activities are often the source of a business's cost advantage. This means the business
can produce a product or service at a lower cost than its competitors.
Introduction to IR 4.0 17
Secondary Activities
The following secondary activities support the various primary activities:
• Procurement and purchasing. Finding new external vendors, maintaining vendor
relationships, and negotiating prices and other activities related to bringing in the
necessary materials and resources used to build a product or service.
• Human resource management. The management of human capital. This includes
functions such as hiring, training, building and maintaining an organizational culture;
and maintaining positive employee relationships.
• Technology development. Activities such as research and development, IT
management and cybersecurity that build and maintain an organization's use of
technology.
• Company infrastructure. Necessary company activities such as legal, general
management, administrative, accounting, finance, public relations and quality
assurance.
Introduction to IR 4.0 18
The value chain framework helps organizations understand and evaluate sources of positive
and negative cost efficiency. Conducting a value chain analysis can help businesses in the
following ways:
• Support decisions for various business activities.
• Diagnose points of ineffectiveness for corrective action.
• Understand linkages and dependencies between different activities and areas in the
business. For example, issues in human resources management and technology can
permeate nearly all business activities.
• Optimize activities to maximize output and minimize organizational expenses.
• Potentially create a cost advantage over competitors.
• Understand core competencies and areas of improvement.
A value chain analysis can offer important benefits; however, when emphasizing granular
process details in a value chain, it's important to still give proper attention to an organization's
broader strategy.
Introduction to IR 4.0 19
When undergoing a value chain analysis, businesses should regard the framework as a starting
point rather than a complete start-to-finish process.
Here are some steps that companies can take to understand their value chains:
• Break each primary and secondary activity down into sub activities. Organizations can
then analyse each function on a more granular level, to compare the financial return
of each function to the time, effort and cost required.
• Look for connections between sub activities. Often, the inefficiency of one activity or
sub activity is linked to another. For example, an ill-advised HR hire can create issues
that permeate into many different sub activities. Technology and inbound operations
can also have rippling effects throughout a company's value chain.
• Diagnose areas of improvement. Consider trends and patterns in the different sub
activities and connections between sub activities, and evaluate for potential
improvement opportunities in those particular points in the value chain.
Introduction to IR 4.0 20
- CHAPTER 3 -
PILLAR 2 – INDUSTRIAL INTERNET OF THINGS
Objectives:
• To understand more Internet of Things (IoT)
• To learn about the important of IoT
• To understand the benefits of IoT to organizations
• To learn about the pros and cons of IoT
• To understand the Industrial IoT Use Cases and Applications
The internet of things, or IoT, is a system of interrelated computing devices, mechanical and
digital machines, objects, animals or people that are provided with unique identifiers (UIDs)
and the ability to transfer data over a network without requiring human-to-human or human-
to-computer interaction.
A thing in the internet of things can be a person with a heart monitor implant, a farm animal
with a biochip transponder, an automobile that has built-in sensors to alert the driver when tire
pressure is low or any other natural or man-made object that can be assigned an Internet
Protocol (IP) address and is able to transfer data over a network.
Increasingly, organizations in a variety of industries are using IoT to operate more efficiently,
better understand customers to deliver enhanced customer service, improve decision-making
and increase the value of the business.
Introduction to IR 4.0 21
The connectivity, networking and communication protocols used with these web-enabled
devices largely depend on the specific IoT applications deployed.
IoT can also make use of artificial intelligence (AI) and machine learning to aid in making data
collecting processes easier and more dynamic.
Introduction to IR 4.0 22
The internet of things helps people live and work smarter, as well as gain complete control over
their lives. In addition to offering smart devices to automate homes, IoT is essential to business.
IoT provides businesses with a real-time look into how their systems really work, delivering
insights into everything from the performance of machines to supply chain and logistics
operations.
IoT enables companies to automate processes and reduce labour costs. It also cuts down on
waste and improves service delivery, making it less expensive to manufacture and deliver
goods, as well as offering transparency into customer transactions.
As such, IoT is one of the most important technologies of everyday life, and it will continue to
pick up steam as more businesses realize the potential of connected devices to keep them
competitive.
Introduction to IR 4.0 23
IoT encourages companies to rethink the ways they approach their businesses and gives them
the tools to improve their business strategies.
IoT can benefit farmers in agriculture by making their job easier. Sensors can collect data on
rainfall, humidity, temperature and soil content, as well as other factors, that would help
automate farming techniques.
The ability to monitor operations surrounding infrastructure is also a factor that IoT can help
with. Sensors, for example, could be used to monitor events or changes within structural
buildings, bridges and other infrastructure. This brings benefits with it, such as cost saving, saved
time, quality-of-life workflow changes and paperless workflow.
A home automation business can utilize IoT to monitor and manipulate mechanical and
electrical systems in a building. On a broader scale, smart cities can help citizens reduce waste
and energy consumption.
Introduction to IR 4.0 24
According to the BCG, 50% of IoT spending will be driven by discrete manufacturing,
transportation and logistics, and utilities by 2020.
But what drives the adoption of IoT in manufacturing? After all, companies don’t have IoT
problems – they have business problems.
According to IDC, the leading use case for IoT in manufacturing is manufacturing operations.
In 2016, this accounted for $102.5 billion out of $178 billion in total spending.
In this chapter, we’ll go over eight specific business use cases and applications in
manufacturing operations, production asset management, and field services that are driving
the adoption of Industrial IoT in manufacturing.
Introduction to IR 4.0 26
i. Production Visibility
Industrial IoT can connect machines, tools, and sensors on the shop floor to give
process engineers and managers much-needed visibility into production. For example,
organizations can automatically track parts as they move through assemblies using
sensors such as RFID and break beams. Furthermore, by connecting with the tools the
operators use to perform their jobs and with the machines involved in the production,
Industrial IoT applications can give supervisors and plant managers a real-time view of
their teams’ yield. This level of visibility can be used by organizations to identify
bottlenecks, find the root cause of problems, and improve at a faster rate.
- CHAPTER 4 -
PILLAR 3 – AUTONOMOUS ROBOTS
Objectives:
• To understand more about Autonomous Robots
• To learn more about Robots types
• To learn more about Robot and Industrial Revolution
• To learn about the pros and cons of IoT
• To understand the Industrial IoT Use Cases and Applications
Autonomous robots have the ability to gain information about their environments, and work
for an extended period of time without human intervention. Examples of these robots range
from autonomous helicopters to robot vacuum cleaners. These self-reliant robots can move
themselves throughout the operation without human assistance, and are able to avoid
situations that are harmful to themselves or people and property. Autonomous robots are also
likely to adapt to changing surroundings.
Introduction to IR 4.0 29
Simpler autonomous robots use infrared or ultrasound sensors to see obstacles, allowing them
to navigate around the obstacles without human control. More advanced robots use stereo
vision to see their environments; cameras give them depth perception, and software allows
them to locate and classify objects in real time.
Autonomous robots are helpful in busy environments, like a hospital. Instead of employees
leaving their posts, an autonomous robot can deliver lab results and patient samples
expeditiously. Without traditional guidance, these robots can navigate the hospital hallways,
and can even find alternate routes when another is blocked. They will stop at pick-up points,
and collect samples to bring to the lab.
DARPA, the Defense Advanced Research Projects Agency, is a division of the US Defense
Department with the mission to create technological surprise for our enemies. This organization
represents the cutting edge of military and disaster relief technology, and after developing
autonomous vehicles, they are focused on creating autonomous robots that are capable of
performing complex tasks in dangerous environments.
Another place autonomous robots are useful is in our natural environment. In 2013, researchers
at Virginia Tech developed an autonomous robotic jellyfish with the intent of one day
conducting undersea military surveillance or monitoring the environment. The 5 foot 7 inch
jellyfish has a long duration and range of operation.
While major robotics companies like FANUC, ABB, KUKA, Universal Robots, and Motoman all
offer autonomous robots, the Robotarium X Zoo houses 45 autonomous robots powered by
photo-voltaic energy. This “first zoo for artificial life” provides an ideal environment for robotic
development.
As emerging technologies become more prominent, the relationship between humans and
robots is evolving. Autonomous robots have the ability to replace humans, such as a cognitive
virtual assistant acting as an automated customer representative. Autonomous robots even
have the ability to understand the emotion in a human’s voice. These trends towards robotic
involvement in industry processes will allow companies to improve productivity and customer
experience, and gain a competitive advantage.
Introduction to IR 4.0 30
i. Pre-Programmed Robots
Pre-programmed robots operate in a controlled environment where they do simple,
monotonous tasks. An example of a pre-programmed robot would be a mechanical
arm on an automotive assembly line. The arm serves one function — to weld a door
on, to insert a certain part into the engine, etc. — and its job is to perform that task
longer, faster and more efficiently than a human.
v. Augmenting Robots
Augmenting robots either enhance current human capabilities or replace the
capabilities a human may have lost. The field of robotics for human augmentation is a
field where science fiction could become reality very soon, with bots that have the
ability to redefine the definition of humanity by making humans faster and stronger.
Some examples of current augmenting robots are robotic prosthetic limbs or
exoskeletons used to lift hefty weights.
As the global manufacturing industry enters its fourth revolution, innovations such as robotics,
automation and artificial intelligence (AI) are set to take over.
The number of active industrial robots worldwide is increasing by approximately 14% year on
year, and automation continues to create new types of robots with improved utility and
function.
Factories of the future will likely feature robots and humans working side-by-side to meet
consumer demand—a new world which business owners should be prepared for.
Introduction to IR 4.0 32
The human race has collectively experienced three industrial revolutions since the 1800s; each
revolution has been characterized by an exciting new technology that improved
manufacturing and processes for the better. The steam engine, the assembly line, and the
computer have each been the catalyst for prior revolutions.
Industry 4.0 refers to the current industrial revolution that we find ourselves in, led by the
evolution of robotics, automation, and the internet of things (IoT). Industry 4.0 heralds an age
of ‘smart’ systems and digital integration; the name was coined in 2011, and the associated
movement is sending ripples through almost every industry around the globe.
Let’s explore some of the ways in which Emerging Industry 4.0 Technologies can positively
affect manufacturing and supply chains.
- CHAPTER 5 -
PILLAR 4 – ADDITIVE MANUFACTURING
Objectives:
• To understand more about Additive Manufacturing
• To learn more about Additive vs Subtractive Manufacturing
• To learn more about 3 Types of Manufacturing
• To learn about the pros and cons of IoT
• To understand the Industrial IoT Use Cases and Applications
Additive manufacturing is relevant in many areas and for numerous industries. Whether used
for building visual and functional prototypes or small and medium series - and increasingly for
series production. This method offers convincing advantages conventional methods cannot
achieve.
Product development and market entry can be significantly accelerated, agile product
customization and functional integration can be achieved more quickly and at a lower cost.
In this way, additive manufacturing gives large OEM manufacturers from a wide variety of
industries the opportunity to differentiate themselves on the market in terms of customer
benefits, cost reduction potential and sustainability targets.
Introduction to IR 4.0 36
GE Additive specializes in developing Powder Bed Fusion (PBF) machines for the additive
manufacturing of metal parts. The three processes GE offers with in the PBF category,
recognized by the American Society for Testing and Materials (ASTM), include: Direct Metal
Laser Melting (DMLM), Electron Beam Melting (EBM), Binder Jetting.
In all of GE Additive’s machines the process involves the spreading of the metal powder layer
by layer and uses either a laser or electron beam to melt and fuse powder together to create
a part. The process repeats until the entire part is created. Loose or unfused powder is removed
during post processing and is recycled for the next build.
Introduction to IR 4.0 37
While some subtractive manufacturing may use manual labour, it’s most often applied at scale
with controlled machining. The equipment is guided by Computer Numerical Control (CNC).
Like Additive Manufacturing, CNC Machining requires a digital model. This approach is most
often used for larger products where quality and speed are crucial.
• Additive Manufacturing:
o Doesn’t require oversight or extensive employee training
o Intricate shapes or hollow objects are easy to create
o More cost-effective
o Less wasted material
o Surface finishes will require an extra step in post-production
o Better suited for smaller products, especially plastics parts
o Finished products have a less reliable quality
o Often slower production, especially with larger products
Introduction to IR 4.0 38
• Subtractive Manufacturing:
o Requires a trained operator to control the machinery and oversee production
o Can easily create a variety of finishes
o Suited for creating large objects, especially from metal
o Faster production
o Finish products more reliably
o More wasted materials
o Generally, more expensive than additive processes
o It’s more difficult to mill intricate shapes and undercuts
Introduction to IR 4.0 39
Most of us identify manufacturing processes by the equipment used. But manufacturing is also
identified in a broader sense, by the way, the manufacturing is being accomplished. A single
way a product is produced can be done by a variety of machines and tools.
This lesson will describe three types, or ways, of manufacturing a product; additive, subtractive,
and forming.
Some additive processes use a liquid material, others use material in a powder form. A
variety of materials, both plastic, and metal are available to provide the unique
attributes needed to satisfy the engineering requirements of the part.
Introduction to IR 4.0 40
Advantages of additive manufacturing over others are the speed, low labour cost,
customization ability, and the ability to make highly complex geometric designs.
Injection molding is a way to manufacture goods using the formative process. A mold
is made in the form of the part needed. Melted plastic is forced into the cavity of the
mold. The material cools and hardens and takes on the form of the mold's design. Then
the newly formed part is removed and the mold refilled.
Introduction to IR 4.0 41
- CHAPTER 6 -
PILLAR 5 – HORIZONTAL AND VERTICAL INTEGRATION
Objectives:
• To understand more about vertical integration vs. Horizontal integration in
business
• To learn about the differences between horizontal integration and vertical
integration
It helps the organizations to achieve synergy, but not with self-sufficiency to operate alone in
the value chain. There have been different opinions and debates on the differences and
similarities between vertical integration and horizontal integration in business. That’s why we’ve
composed this informative guide to help you know the differences as well as the similarities of
these two terms in the world of business.
Introduction to IR 4.0 42
Take, for instance, when a biscuit company acquires its rival biscuit-making company to
benefit from economies of scale, expand geographically, and increase the market share, it is
called horizontal integration. Some of the best examples of horizontal integration include
Disney merging with Pixar, Porsche merging with Volkswagen, and Quaker Oats with Snapple.
In 2006, Walt Disney Company acquired Pixar Animation Studios for $7.4 billion. They acquired
this company to diversity their services and to achieve growth in their operational size and
economies of scale due to increased production levels. This helps Disney in spanning its reach
to a larger market with a larger customer base.
Introduction to IR 4.0 43
There are two major forms of vertical integration. This includes forward and backward
integration. Forward integration involves the company taking complete control and ownership
of its distributors or customers, while backward integration involves a company taking control
and ownership over its suppliers or the production of its own product line. One of the reasons
why vertical integration is more preferable is that it helps to lower the risk a firm will have to
face in the industry.
Introduction to IR 4.0 44
- CHAPTER 7 -
PILLAR 6 – SIMULATION AND AUGMENTED REALITY
Objectives:
• To understand more about augmented reality
• To learn more about how does augmented reality work
• To learn more about how to take digitalized steps in the analogue world
Augmented reality continues to develop and become more pervasive among a wide range
of applications. Since its conception, marketers and technology firms have had to battle the
perception that augmented reality is little more than a marketing tool. However, there is
evidence that consumers are beginning to derive tangible benefits from this functionality and
expect it as part of their purchasing process.
For example, some early adopters in the retail sector have developed technologies that are
designed to enhance the consumer shopping experience. By incorporating augmented
reality into catalogue apps, stores let consumers visualize how different products would look
like in different environments. For furniture, shoppers point the camera at the appropriate room
and the product appears in the foreground.
Introduction to IR 4.0 46
Amid the rise of data collection and analysis, one of augmented reality’s primary goals is to
highlight specific features of the physical world, increase understanding of those features, and
derive smart and accessible insight that can be applied to real-world applications. Such big
data can help inform companies' decision-making and gain insight into consumer spending
habits, among others.
Key Takeaways
• Augmented reality (AR) involves overlaying visual, auditory, or other sensory
information onto the world in order to enhance one's experience.
• Retailers and other companies can use augmented reality to promote products or
services, launch novel marketing campaigns, and collect unique user data.
• Unlike virtual reality, which creates its own cyber environment, augmented reality adds
to the existing world as it is.
Introduction to IR 4.0 47
So now that you know the meaning of AR, how does it work? First, computer vision understands
what is in the world around the user from the content of the camera feed. This allows it to show
digital content relevant to what the user is looking at. This digital content is then displayed in a
realistic way, so that it looks part of the real world - this is called rendering. Before breaking this
down into more detail, let’s use a concrete example to make this clearer. Consider playing an
augmented reality board game using a real cereal box as the physical support like in the figure
below.
First, computer vision processes the raw image from the camera, and recognizes the cereal
box. This triggers the game. The rendering module augments the original frame with the AR
game making sure it precisely overlaps with the cereal box. For this it uses the 3D position and
orientation of the box determined by computer vision. Since augmented reality is live, all the
above has to happen every time a new frame comes from the camera. Most modern phones
work at 30 frames per second, which gives us only 30 milliseconds to do all this. In many cases
the AR feed you see through the camera is delayed by roughly 50 ms to allow all this to
happen, but our brain does not notice!
Introduction to IR 4.0 48
Geometry answers the “where?” question, and infers where the cereal box or the face are in
the 3D world, and which way they are facing. Without geometry, AR content cannot be
displayed at the right place and angle, which is essential to make it feel part of the physical
world. Often, we need to develop new techniques for each domain. For example, computer
vision methods that work for a cereal box are quite different from those used for a face.
4. Comfort
Make comfortable designs to prevent physical strains and reduce cognitive load.
5. Security
AR data is rich; so, design to ensure users’ data is secure.
Introduction to IR 4.0 51
- CHAPTER 8 -
PILLAR 7 – CYBER SECURITY
Objectives:
• To understand more about cyber security
• To learn more about how does augmented reality work
• To learn more about the scale and types of the cyber threat
• To learn more about cyber security and the fourth industrial revolution
Ideally, the Industry 4.0 requires a completely interconnected reality, but this same
characteristic uncovers an unexpected vulnerability. Because with connectivity, the effect
and impact of eventual attacks grow as well.
Introduction to IR 4.0 52
Cyber security is the practice of defending computers, servers, mobile devices, electronic
systems, networks, and data from malicious attacks. It's also known as information technology
security or electronic information security. The term applies in a variety of contexts, from
business to mobile computing, and can be divided into a few common categories.
• Network security is the practice of securing a computer network from intruders, whether
targeted attackers or opportunistic malware.
• Application security focuses on keeping software and devices free of threats. A
compromised application could provide access to the data its designed to protect.
Successful security begins in the design stage, well before a program or device is
deployed.
• Information security protects the integrity and privacy of data, both in storage and in
transit.
• Operational security includes the processes and decisions for handling and protecting
data assets. The permissions users have when accessing a network and the procedures
that determine how and where data may be stored or shared all fall under this
umbrella.
• Disaster recovery and business continuity define how an organization responds to a
cyber-security incident or any other event that causes the loss of operations or data.
Disaster recovery policies dictate how the organization restores its operations and
information to return to the same operating capacity as before the event. Business
continuity is the plan the organization falls back on while trying to operate without
certain resources.
Introduction to IR 4.0 53
Medical services, retailers and public entities experienced the most breaches, with malicious
criminals responsible for most incidents. Some of these sectors are more appealing to
cybercriminals because they collect financial and medical data, but all businesses that use
networks can be targeted for customer data, corporate espionage, or customer attacks.
With the scale of the cyber threat set to continue to rise, the International Data Corporation
predicts that worldwide spending on cyber-security solutions will reach a massive $133.7 billion
by 2022. Governments across the globe have responded to the rising cyber threat with
guidance to help organizations implement effective cyber-security practices.
In the U.S., the National Institute of Standards and Technology (NIST) has created a cyber-
security framework. To combat the proliferation of malicious code and aid in early detection,
the framework recommends continuous, real-time monitoring of all electronic resources.
The importance of system monitoring is echoed in the “10 steps to cyber security”, guidance
provided by the U.K. government’s National Cyber Security Centre. In Australia, The Australian
Cyber Security Centre (ACSC) regularly publishes guidance on how organizations can counter
the latest cyber-security threats.
Introduction to IR 4.0 54
So, how do malicious actors gain control of computer systems? Here are some common
methods used to threaten cyber-security:
Malware
Malware means malicious software. One of the most common cyber threats, malware is
software that a cybercriminal or hacker has created to disrupt or damage a legitimate user’s
computer. Often spread via an unsolicited email attachment or legitimate-looking download,
malware may be used by cybercriminals to make money or in politically motivated cyber-
attacks.
SQL injection
An SQL (structured language query) injection is a type of cyber-attack used to take control of
and steal data from a database. Cybercriminals exploit vulnerabilities in data-driven
applications to insert malicious code into a databased via a malicious SQL statement. This
gives them access to the sensitive information contained in the database.
Introduction to IR 4.0 55
Phishing
Phishing is when cybercriminals target victims with emails that appear to be from a legitimate
company asking for sensitive information. Phishing attacks are often used to dupe people into
handing over credit card data and other personal information.
Man-in-the-middle attack
A man-in-the-middle attack is a type of cyber threat where a cybercriminal intercepts
communication between two individuals in order to steal data. For example, on an unsecure
WiFi network, an attacker could intercept data being passed from the victim’s device and the
network.
Denial-of-service attack
A denial-of-service attack is where cybercriminals prevent a computer system from fulfilling
legitimate requests by overwhelming the networks and servers with traffic. This renders the
system unusable, preventing an organization from carrying out vital functions.
Fourth IR environments are technical worlds of features that enable such things as the
provisioning of servers, initiating production via a command-and-control node, the rapid
instantiation and use of encrypted data vaults and containers, and adoption of open-source
code.
Manufacturing execution systems (MES) are among the key technical elements of OT and BA
in these facilities. MESs are functionally highly sophisticated logic layers utilizing cloud and on-
prem-based data vaults to specify production or machine procedural steps. They also function
as a component of the interface between the operator and the firm’s physical processes. A
principal vulnerability is that these systems often have API access to the firm’s enterprise
resource planning (ERP) system.
Introduction to IR 4.0 56
MESs mirror purer CPS as they can be both open or closed systems, often with feedback loops
and built-in intelligence. It is here that the impact of a system compromise can be most
impactful as attackers can effectively affect segments or all the firm’s manufacturing
capabilities.
It is important to note the “tipping point” concept about a cyberattack. Simply stated, to
obtain the desired outcomes, a bad actor need not “bring down” the entire system but only
the components necessary to force the desired outcome — i.e., paying a ransom.
This unmistakable shift toward dense technical ecosystems is indeed creating its intended
benefits, but it has also created new attack vectors. Multisector attacks cantered on ML are
now commonplace and include newly seen integrity attacks, advanced remote and indirect
compromise attacks.
Upon gaining entry to the firm’s systems, bad actors will move laterally, often compromising
the entire IT and OT system — with devastating results. Actors have specifically targeted
programmable manufacturing machines and MES as critical nodes of the overall ecosystem.
Hackers have also taken notice of the human-computer interfaces (HCI) that are central to
operations with vulnerabilities that are often poorly understood by their owners. Adversarial
machine learning (AML) is also being leveraged by actors to breach networks in the form of
integrity attacks designed to confuse and corrupt the ML being employed by the firm.
Introduction to IR 4.0 57
- CHAPTER 9 -
PILLAR 8 – CLOUD COMPUTING
Objectives:
• To understand more about cloud computing
• To learn more about cloud computing service
• To learn more about the important of cloud
• To learn more about Cyber Security and The Fourth Industrial Revolution
Compared to traditional on-premises IT, and depending on the cloud services you select,
cloud computing helps do the following:
• Lower IT costs
Cloud lets you offload some or most of the costs and effort of purchasing, installing,
configuring, and managing your own on-premises infrastructure.
The term ‘cloud computing’ also refers to the technology that makes cloud work. This includes
some form of virtualized IT infrastructure—servers, operating system software, networking, and
other infrastructure that’s abstracted, using special software, so that it can be pooled and
divided irrespective of physical hardware boundaries. For example, a single hardware server
can be divided into multiple virtual servers.
Virtualization enables cloud providers to make maximum use of their data centre resources.
Not surprisingly, many corporations have adopted the cloud delivery model for their on-
premises infrastructure so they can realize maximum utilization and cost savings vs. traditional
IT infrastructure and offer the same self-service and agility to their end-users.
If you use a computer or mobile device at home or at work, you almost certainly use some
form of cloud computing every day, whether it’s a cloud application like Google Gmail or
Salesforce, streaming media like Netflix, or cloud file storage like Dropbox. According to a
recent survey, 92% of organizations use cloud today (link resides outside IBM), and most of
them plan to use it more within the next year.
Introduction to IR 4.0 59
• SaaS (Software-as-a-Service)
o SaaS—also known as cloud-based software or cloud applications—is
application software that’s hosted in the cloud and that you access and use
via a web browser, a dedicated desktop client, or an API that integrates with
your desktop or mobile operating system. In most cases, SaaS users pay a
monthly or annual subscription fee; some may offer ‘pay-as-you-go’ pricing
based on your actual usage.
o In addition to the cost savings, time-to-value, and scalability benefits of cloud,
SaaS offers the following:
o Automatic upgrades: With SaaS, you take advantage of new features as soon
as the provider adds them, without having to orchestrate an on-premises
upgrade.
o SaaS is the primary delivery model for most commercial software today—there
are hundreds of thousands of SaaS solutions available, from the most focused
industry and departmental applications, to powerful enterprise software
database and AI (artificial intelligence) software.
• PaaS (Platform-as-a-Service)
o PaaS provides software developers with on-demand platform—hardware,
complete software stack, infrastructure, and even development tools—for
running, developing, and managing applications without the cost, complexity,
and inflexibility of maintaining that platform on-premises.
o With PaaS, the cloud provider hosts everything—servers, networks, storage,
operating system software, middleware, databases—at their data centre.
Developers simply pick from a menu to ‘spin up’ servers and environments they
need to run, build, test, deploy, maintain, update, and scale applications.
o Today, PaaS is often built around containers, a virtualized compute model one
step removed from virtual servers. Containers virtualize the operating system,
enabling developers to package the application with only the operating
system services it needs to run on any platform, without modification and
without need for middleware.
Introduction to IR 4.0 60
o Red Hat OpenShift is a popular PaaS built around Docker containers and
Kubernetes, an open source container orchestration solution that automates
deployment, scaling, load balancing, and more for container-based
applications.
• IaaS (Infrastructure-as-a-Service)
o IaaS provides on-demand access to fundamental computing resources–
physical and virtual servers, networking, and storage—over the internet on a
pay-as-you-go basis. IaaS enables end users to scale and shrink resources on
an as-needed basis, reducing the need for high, up-front capital expenditures
or unnecessary on-premises or ‘owned’ infrastructure and for overbuying
resources to accommodate periodic spikes in usage.
o In contrast to SaaS and PaaS (and even newer PaaS computing models such
as containers and serverless), IaaS provides the users with the lowest-level
control of computing resources in the cloud.
o IaaS was the most popular cloud computing model when it emerged in the
early 2010s. While it remains the cloud model for many types of workloads, use
of SaaS and PaaS is growing at a much faster rate.
Introduction to IR 4.0 61
Indeed, it's increasingly clear that when it comes to enterprise computing platforms, like it or
not, the cloud has won.
Tech analyst Gartner predicts that as much as half of spending across application software,
infrastructure software, business process services and system infrastructure markets will have
shifted to the cloud by 2025, up from 41% in 2022. It estimates that almost two-thirds of spending
on application software will be via cloud computing, up from 57.7% in 2022.
That's a shift that only gained momentum in 2020 and 2021 as businesses accelerated their
digital transformation plans during the pandemic. The lockdowns throughout the pandemic
showed companies how important it was to be able to access their computing infrastructure,
applications and data from wherever their staff were working – and not just from an office.
Gartner said that demand for integration capabilities, agile work processes and composable
architecture will drive the continued shift to the cloud.
The scale of cloud spending continues to rise. For the full year 2021, tech analyst IDC expects
cloud infrastructure spending to have grown 8.3% compared to 2020 to $71.8 billion, while non-
cloud infrastructure is expected to grow just 1.9% to $58.4 billion. Long term, the analyst expects
Introduction to IR 4.0 62
spending on compute and storage cloud infrastructure to see a compound annual growth
rate of 12.4% over the 2020-2025 period, reaching $118.8 billion in 2025, and it will account for
67.0% of total compute and storage infrastructure spend. Spending on non-cloud infrastructure
will be relatively flat in comparison and reach $58.6 billion in 2025.
All predictions around cloud-computing spending are pointing in the same direction, even if
the details are slightly different. The momentum they are describing is the same: tech analyst
Canalys reports that worldwide cloud infrastructure services expenditure topped $50 billion in
a quarter for the first time in Q4 2021. For the full year, it has cloud infrastructure services
spending growing 35% to $191.7 billion.
Canalys argues that there is already a new growth opportunity for cloud on the horizon, in the
form of augmented and virtual reality and the metaverse. "This will be a significant driver for
both cloud services spend and infrastructure deployment over the next decade.
Introduction to IR 4.0 63
- CHAPTER 10 -
PILLAR 9 – BIG DATA ANALYSIS
Objectives:
• To understand more about big data
• To learn more about types of big data
• To learn more about the important of cloud
• To learn more about characteristics of big data
• To learn more about advantages of big data processing
•
There’s much wisdom in that saying, which has been attributed to both W. Edwards Deming
and Peter Drucker, and it explains why the recent explosion of digital data is so important.
Simply put, because of big data, managers can measure, and hence know, radically more
about their businesses, and directly translate that knowledge into improved decision making
and performance.
Consider retailing. Booksellers in physical stores could always track which books sold and which
did not. If they had a loyalty program, they could tie some of those purchases to individual
customers. And that was about it. Once shopping moved online, though, the understanding
of customers increased dramatically. Online retailers could track not only what customers
bought, but also what else they looked at; how they navigated through the site; how much
they were influenced by promotions, reviews, and page layouts; and similarities across
individuals and groups. Before long, they developed algorithms to predict what books
individual customers would like to read next—algorithms that performed better every time the
customer responded to or ignored a recommendation. Traditional retailers simply couldn’t
access this kind of information, let alone act on it in a timely manner. It’s no wonder that
Amazon has put so many brick-and-mortar bookstores out of business.
The familiarity of the Amazon story almost masks its power. We expect companies that were
born digital to accomplish things that business executives could only dream of a generation
ago. But in fact, the use of big data has the potential to transform traditional businesses as
well. It may offer them even greater opportunities for competitive advantage (online
businesses have always known that they were competing on how well they understood their
data).
Introduction to IR 4.0 64
As we’ll discuss in more detail, the big data of this revolution is far more powerful than the
analytics that were used in the past. We can measure and therefore manage more precisely
than ever before. We can make better predictions and smarter decisions. We can target
more-effective interventions, and can do so in areas that so far have been dominated by gut
and intuition rather than by data and rigor.
As the tools and philosophies of big data spread, they will change long-standing ideas about
the value of experience, the nature of expertise, and the practice of management. Smart
leaders across industries will see using big data for what it is: a management revolution. But as
with any other major change in business, the challenges of becoming a big data–enabled
organization can be enormous and require hands-on—or in some cases hands-off—
leadership. Nevertheless, it’s a transition that executives need to engage with today.
Introduction to IR 4.0 65
The New York Stock Exchange is an example of Big Data that generates about one terabyte
of new trade data per day.
Social Media. The statistic shows that 500+terabytes of new data get ingested into the
databases of social media site Facebook, every day. This data is mainly generated in terms of
photo and video uploads, message exchanges, putting comments etc.
Introduction to IR 4.0 66
A single Jet engine can generate 10+terabytes of data in 30 minutes of flight time. With many
thousand flights per day, generation of data reaches up to many Petabytes.
Introduction to IR 4.0 67
10.3.1 Structured
Any data that can be stored, accessed and processed in the form of fixed format is termed
as a ‘structured’ data. Over the period of time, talent in computer science has achieved
greater success in developing techniques for working with such kind of data (where the format
is well known in advance) and also deriving value out of it. However, nowadays, we are
foreseeing issues when a size of such data grows to a huge extent, typical sizes are being in
the rage of multiple zettabytes.
Looking at these figures one can easily understand why the name Big Data is given and
imagine the challenges involved in its storage and processing.
10.3.2 Unstructured
Any data with unknown form or the structure is classified as unstructured data. In addition to
the size being huge, un-structured data poses multiple challenges in terms of its processing for
deriving value out of it. A typical example of unstructured data is a heterogeneous data
source containing a combination of simple text files, images, videos etc. Now day
organizations have wealth of data available with them but unfortunately, they don’t know
how to derive value out of it since this data is in its raw form or unstructured format.
10.3.3 Semi-structured
Semi-structured data can contain both the forms of data. We can see semi-structured data
as a structured in form but it is actually not defined with e.g. a table definition in relational
DBMS. Example of semi-structured data is a data represented in an XML file.
Examples of Semi-structured Data
Please note that web application data, which is unstructured, consists of log files, transaction
history files etc. OLTP systems are built to work with structured data wherein data is stored in
relations (tables).
Introduction to IR 4.0 70
(i) Volume
The name Big Data itself is related to a size which is enormous. Size of data plays a
very crucial role in determining value out of data. Also, whether a particular data
can actually be considered as a Big Data or not, is dependent upon the volume of
data. Hence, ‘Volume’ is one characteristic which needs to be considered while
dealing with Big Data solutions.
(ii) Variety
The next aspect of Big Data is its variety.
Variety refers to heterogeneous sources and the nature of data, both structured
and unstructured. During earlier days, spreadsheets and databases were the only
sources of data considered by most of the applications. Nowadays, data in the
form of emails, photos, videos, monitoring devices, PDFs, audio, etc. are also being
considered in the analysis applications. This variety of unstructured data poses
certain issues for storage, mining and analysing data.
(iii) Velocity
The term ‘velocity’ refers to the speed of generation of data. How fast the data is
generated and processed to meet the demands, determines real potential in the
data.
Big Data Velocity deals with the speed at which data flows in from sources like
business processes, application logs, networks, and social media sites, sensors,
Mobile devices, etc. The flow of data is massive and continuous.
(iv) Variability
This refers to the inconsistency which can be shown by the data at times, thus
hampering the process of being able to handle and manage the data effectively.
Introduction to IR 4.0 71
• Access to social data from search engines and sites like Facebook, twitter is enabling
organizations to fine tune their business strategies.
o Improved customer service
• Traditional customer feedback systems are getting replaced by new systems designed
with Big Data technologies. In these new systems, Big Data and natural language
processing technologies are being used to read and evaluate consumer responses.
• Big Data technologies can be used for creating a staging area or landing zone for new
data before identifying what data should be moved to the data warehouse. In
addition, such integration of Big Data technologies and data warehouse helps an
organization to offload infrequently accessed data.