The fourth industrial revolution, commonly referred to as Industry 4.0, has already begun to transform the world of manufacturing. By integrating technologies such as the Internet of Things (IoT), artificial intelligence (AI), advanced robotics, cloud computing and big data, Industry 4.0 is radically changing the way companies produce goods and manage their operations.
Despite the scale of the challenges involved in transitioning to this new era, several major industrial groups have successfully leveraged Industry 4.0 to improve their efficiency, flexibility and competitiveness. Companies such as Siemens, General Electric, Bosch, Toyota, Daimler and Volkswagen have invested heavily in digitizing their production processes, illustrating the potential of this industrial revolution.
In this article, we'll explore how these industry giants have successfully made the transition to Industry 4.0.
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Table of Contents
1. SIEMENS:
Siemens is one of the major players in Industry 4.0, both as a service provider for other companies and for its own factories. One of the most remarkable examples of this digital transformation is the Siemens Electronic Works Amberg (EWA) plant, located in Amberg, Germany.
Siemens EWA factory an example of efficient automation
At this plant, Siemens produces a variety of products, including programmable controllers or Simatic PLCs, with around 17 million units produced each year. These devices are used to control factories, machines and automate industrial production.
However, the truly remarkable aspect is that the plant's own production is controlled by 2,800 Simatic parts. This integration of its own products into the production process enables a high degree of automation, with 75% of production controlled by machines and robots.
Outstanding quality thanks to Industrie 4.0
Thanks to this automation, EWA produced with a quality level of 99.9990%, a result that makes this plant a benchmark in industrial production. It's tangible proof of how Industry 4.0 can improve production quality and efficiency.
By using its own products to automate production, Siemens is demonstrating not only the reliability and efficiency of its products, but also how Industry 4.0 can be successfully implemented to improve production.
2. Bosch :
Bosch, another industry heavyweight, has also embraced the Industry 4.0 movement with conviction. So, how has Bosch negotiated this transition? Let's explore it together.
What was Bosch's approach to Industry 4.0?
Industry 4.0 has always been a priority for Bosch and its industrial division, Bosch Rexroth. Drawing on its dual expertise as a manufacturer and user of its solutions, Bosch has used its experience to develop innovative solutions. The aim? To make production more flexible, agile and adaptable, with a stronger customer focus.
How has Bosch put its vision of Industry 4.0 into practice?
Bosch has developed solutions for its own plants before offering them to its customers. This method was developed over eight years of diverse projects and in-depth thinking on Industry 4.0. Bosch has formulated tools around four main axes: the connected value chain, operator assistance, adaptive production and the integration of intelligent products.
How has Bosch contributed to training and skills development for Industry 4.0?
Bosch has focused on training and skills development for Industry 4.0. The group has launched a training program for employees without a university degree, offering them training for jobs in IT and commerce that typically require a university degree. Bosch has also set up Germany's first nationwide vocational training program to develop the skills required for Industry 4.0.
3. Volkswagen :
Volkswagen, like many other automotive companies, is fully committed to digitalization and Industry 4.0. Let's take a closer look at how far this automotive giant has come.
How much has Volkswagen invested in digitalization and Industry 4.0?
In recent years, Volkswagen has demonstrated a remarkable commitment to digitalization and Industry 4.0. Since announcing their "Digital Transformation Road" in 2019, they have invested up to €4 billion in digitalization projects up to 2023, mainly in administration, but also in production.
How has Volkswagen's production evolved with Industry 4.0?
The application of Industry 4.0 technologies has enabled Volkswagen to make significant advances in production. By 2023, they are able to produce customized cars at the same price as production vehicles without interrupting the production line. Their ability to monitor every stage of production via a single screen is also a testament to their success in implementing these technologies.
Human-robot interaction at Volkswagen: Where are they in 2023?
In Volkswagen's Industrie 4.0 journey, human-robot interaction has been a key element. By 2023, their ability to enable effective interaction between robots and humans has become a model for the industry. This combined the precision of robotics with the expert judgment of humans.
4. Toyota
At present, Toyota is taking a different approach to the predominant trend in the global automotive industry, which is to replace employees with robots. Toyota's philosophy remains human-centric, with the Japanese multinational's managers believing that human involvement in the production process remains indispensable, and that robots should only make the job easier.
More "human" automation: the example of Toyota Motor Manufacturing Kentucky
Toyota puts this philosophy of more "human" automation into practice in its most modern plants. The Toyota Motor Manufacturing Kentucky plant in Georgetown, the Japanese company's largest facility in the world, is a perfect example. Producing more than half a million cars a year - mainly for the American market - this 750,000-square-meter plant manufactures models such as the Toyota Camry, Avalon and Lexus ES.
Recently, a major modernization of the plant was completed at a cost of over $1.3 billion. Despite this considerable investment, employee involvement in car assembly has not diminished. New automation solutions have been implemented, and the company has even hired around 700 additional people.
The role of man in Industry 4.0 at Toyota
The degree of process automation at Toyota is no higher today than it was 15 years ago. According to Wil James, President of Toyota Motor Manufacturing Kentucky, "machines are great for doing repetitive tasks, but they can't improve the efficiency or quality of work. That can only be done by humans.
As a result, Toyota's Industry 4.0 strategy emphasizes the interaction between man and machine, rather than the outright replacement of man by machine. This reflects the company's belief that technology should be used to enhance human work, not replace it completely.
Employee training: an essential part of Toyota's strategy
Since human-machine interaction is at the heart of Toyota's vision for Industry 4.0, training employees in new technologies and processes is an essential component of their strategy. Toyota invests heavily in training to ensure that its employees are well prepared to work effectively with new technologies, while fostering a culture of continuous improvement and innovation.
5. General Electric
General Electric (GE) is a true symbol of American greatness. The company played a decisive role in the transition from the 19th to the 20th century, leaving its mark on technological and industrial evolution. From the development of the filament light bulb to the advent of nuclear power, and the modernization of households after the Second World War with the introduction of televisions, GE played a major role in shaping the modern Western world right up to the 2000s. Had the acronym "GAFAM" existed earlier, the letters "GE" would undoubtedly have featured prominently.
Multinational General Electric (GE) is a pioneer in the transformation of industry through software-defined machines and connected solutions. Active in key sectors such as energy, healthcare and transportation, GE offers a fascinating example of the transition to Industry 4.0.
Predix: Cloud-based platform
GE has achieved a major breakthrough in this transformation with the launch of Predix, a cloud-based Platform as a Service (PaaS). This platform has revolutionized the way GE and its customers understand and manage their operations, providing industrial-scale analysis of production and operations optimization.
Digital Windfarm: Wind Energy Optimization
Another notable development was the creation of Digital Windfarm technology for the wind energy sector. Using sensors, data networks and analytics, Digital Windfarm creates customized turbines to maximize energy efficiency. According to GE, this technology has increased energy production by 20% per year.
The Challenges of Transition
Despite these impressive advances, GE has also encountered challenges in its transition to Industry 4.0. Changes in management and strategy within its GE Digital division highlight the difficulties inherent in change management when adopting new technologies and ways of working.
Conclusion:
After exploring these success stories, perhaps you're considering embarking on a digital transformation for your own company. Industry 4.0 offers unprecedented opportunities to optimize production, improve efficiency and drive innovation. However, the transition to this new industrial era doesn't happen without clear planning and strategy.
