Intelligent sensors the key to Industry 4.0

The Industrial Internet has the potential to become a major competitive advantage within the manufacturing industry. Built on the foundation of the Internet of Things (IoT) — an interconnected web of smart machines and devices that talk to and interact with each other autonomously — Industry 4.0 is altering the manufacturing landscape by creating intelligent networks of machines and systems that will increase horizontal and vertical integration.

From preventive maintenance programs that will help reduce machine downtime, to the ability to track products throughout the supply chain, Industry 4.0, if embraced effectively, will provide the Australian manufacturing industry the opportunity to realise significant operational and functional competitive advantage over industry rivals. Locally we continue to be challenged by a declining manufacturing sector and so to compete we must look to innovate and embrace the transition to the fourth industrial revolution.

The first industrial revolution happened back in the 1700s when the age of steam engine production commenced. It was followed by a second industrial revolution initiated by the adoption of electrical energy in 1870; and then by a third based on the automation of production through the introduction of programmable logic controllers in 1969. Now we are in the midst of a transitioning to the fourth industrial revolution — Industry 4.0 — driven by connected devices and sensors, cloud computing, advanced robotics, intelligent software and a range of other technologies.

Deloitte defines Industry 4.0 as the merging of real and virtual worlds on the factory floor — a world of smart factories where cyber-physical systems monitor physical processes, communicate with each other and human workers, and make automated decisions.

A key driver for the change is the use of sensor-based technology. Sensors provide the senses for machines, and the feedback they provide is what makes intelligent machines possible in the first place. ‘Sensor intelligence’ focuses on one particular aspect of sensor technology: equipping machines with the ability to see, recognise and communicate intelligently.

Intelligent sensors contribute to the ability to classify and interpret information. This is made possible by intelligent signal processing, which derives the truly relevant information from large quantities of data and makes it available at various levels. This is why — in addition to the primary control system for machines and systems — information can be provided for monitoring the production systems themselves (not just the process) and making it possible to detect faults. Transparency of the processes and material flows produces additional potential for optimisation, so that processes become more efficient and cost-effective, and help to increase a manufacturer’s competitiveness.

With the continued decline in the Australian manufacturing sector, the need for Industry 4.0 is heightened. There is no doubt that Australian manufacturing needs to embrace Industry 4.0 and thereby secure the future of the industry through the adoption of innovation and technology to find our place within the global supply chain.

A member of the Extended Management Team for Sick Pty Ltd Australia & New Zealand, Jason Mair is the product market manager responsible for product management, marketing and customer service. Having commenced his working life within the manufacturing sector, Jason has over 25 years of experience across a number of roles in engineering, sales, product management and marketing, and has recently completed his Graduate Diploma in Business Management. He also recognises the challenges facing modern manufacturing facilities in a global market space, having spent 12 years in the manufacturing sector.