Towards factory automation
La Industria 4.0 implica la completa digitalización de las cadenas de valor a través de la integración de tecnologías de procesamiento de datos, software inteligente y sensores; desde los proveedores hasta los clientes, para así poder predecir, controlar, planear, y producir, de forma inteligente, lo que genera mayor valor a toda la cadena.[34].
El objetivo del concepto "Industria 4.0" es el de computarizar el mundo de la fábrica. Esto supone la integración técnica de los sistemas ciberfísicos (SCF) en las actividades de producción y logística, así como el uso de Internet en los procesos industriales.[35].
Lo anterior implica un buen grado de automatización y de digitalización de usinas y fábricas. Recurriendo a Internet y a los sistemas ciber-físicos, o sea, recurriendo a redes virtuales o gemelos digitales con posibilidades de controlar objetos físicos,[36] se pueden ir modernizando las plantas fabriles hasta transformarlas en fábricas inteligentes caracterizadas por una intercomunicación continua e instantánea entre las diferentes estaciones de trabajo que componen las propias cadenas de producción, de aprovisionamiento, y de empaque y despacho. La utilización de captores aporta a las máquinas y herramientas de la planta, una capacidad de autodiagnóstico de situación que permite un control a distancia, asegurando su eventual retiro de servicio como su mejor integración en el sistema productivo global.[37].
Flexibility and customization of production
In an industry 4.0 manufacturing environment, the tools and machines of a factory, together with elements such as warehouses and stocks of raw materials and semi-finished products, ensure links and communications through an internal network linked to the outside, introducing great flexibility in the production process and great adaptability to fortuitous situations, all of which can contribute to the increase and improvement of production.
The particular needs and conveniences of final consumers or clients, as well as intermediaries, suppliers and associates, who are in some way related or involved with the production process itself, or with its inputs, or with its products, can be better contemplated through some degree of customization or adaptation, for example by modifying some characteristics of the products intended for them, or ensuring certain delivery dates or certain delivery times, etc.[38].
Therefore, it will be very possible to manage large-scale production, with personalized products according to particular needs, and at the same time without maintaining excessively voluminous stocks, ensuring good satisfaction to the largest number of customers possible.[39].
New logistics tools
The Industry 4.0 system is capable of generating a regular flow of information, much higher than what could be available if more traditional schemes, logistical strategies, and modes of production were used. Furthermore, this information can be exchanged very quickly, both internally (by direct communication or through an Intranet) and externally (by communication through the Internet), which opens up interesting possibilities with logistical actors external to the production site itself, in the sense that it could easily allow adaptations to changing situations, both internally of the industrial plant or production chain, and at a general level.[40].
The RFID system, for example, can be used as an effective traceability system within the manufacturing site (or production chain), as well as worldwide. From what has been expressed, we can deduce the importance of using a logistics system capable of a very rapid exchange of information between the company or production chain and all of its borrowers or counterparties (the process in question is eminently real-time and not deferred processing or batch processing).
Big data and analytics
Modern information and communication technologies such as cyber-physical systems, big data or cloud computing will help predict the possibility of increasing productivity, quality and flexibility within the manufacturing industry and thus analyze the advantages they have over the competition.
Big data analytics consists of 6 Cs in Industry 4.0 and the cyber-physical environment. The 6 Cs system consists of:.
In this scenario and in order to provide useful and correct information for factory management, the data must be processed with advanced tools (analytics and algorithms) to generate meaningful information. Considering the presence of both visible and invisible facts in an industrial factory, the algorithm information must be able to detect these invisible facts, such as the wear and tear of machines and components in the factory.[41][42].
Simulation tools
The collection of data generated by the different elements of the production chain also makes it possible to produce a virtual replica of all or part of that chain, which also makes it possible to generate simulations of procedures or tests, as well as allowing future workers or technicians to become familiar with the tools and work elements that they have at their disposal, as well as with the exceptional circumstances or complex procedures that could occur.[43].
All this accumulated information could also allow non-specialists to solve some problems that could occur on their own, or better inform higher-level technicians remotely about what they have observed as an irregularity, in order to respond better and more quickly to any out-of-routine event.[44] On the other hand, augmented reality allows factory employees to obtain real-time information[45] that allows them to improve decision-making and work procedures.[46].
Energy and raw materials
It is no longer enough to manage the raw materials involved or produced reasonably well, since the optimization of energy use or energy production is also sought. Likewise, it is no longer enough to manage these factors in delayed time, since decisions need to be made in real time.
Industry 4.0 also aims to provide answers to current problems related to energy saving as well as the management of natural and human resources. With a system organized on the basis of a communications network and instant and permanent exchange of information, you will be much better prepared to make this management better and much more effective, in correspondence with the needs and availability of each element of the system, allowing improvements and gains for productivity as well as the economy of resources.[47].