Industry 4.0 Manufacturing and its Role in Sustainability

          Service management

• Industry 4.0 links measurement instruments to the complete knowledge and automation infrastructure of a manufacturer. This is an extension of collecting, transferring and storing capabilities of vast data volumes related to energy supply use, production and transition. 
• The growth of data and increased access to computer resources enables special AI techniques to facilitate variable detection and analyze trends and patterns in various industries.

          Digitizing and modernizing tracking capabilities 

• By digitizing and modernizing tracking capabilities, businesses can easily eliminate inefficiencies by providing total visibility of a manufacturing plant. Digitization typically involves embedded sensors in manufacturing equipment that connect to cyber-physical systems. The benefits include reduced errors, lower production costs and higher capabilities to meet market demands.

Warehouse environments

          Sustainable smart factories

• Industry 4.0 technologies drive responsible consumption and development for businesses through connected factory equipment, AI-enabled energy systems and IIoT devices.

          Radio Frequency Identification (RFID) and warehousing 

• RFID technology identifies people and objects using radio waves. In a warehouse setting, manufacturers use RFID technology and tags to track products and even locate lost items. RFID can also minimize waste in production and logistics processes because it can replace paper receipts and labels, reduce shipping errors and trace products to cut down on wasted materials. 

          Sustainable buildings

• Digital technologies and building information modeling software can optimize buildings by incorporating elements such as eco-friendly bacteria that naturally repair structures into industrial and commercial structures.
• Energy-efficient heating and cooling systems will self-regulate in real time, saving energy and lowering the cost of electricity for manufacturers. Sensors and IIoT Industry 4.0 devices can tell environmental control systems to switch off the lights and air conditioning when people leave a building.
• Purolator’s National Hub was designed to meet the requirements of the Toronto Green Standards program and optimize shipping efficiency. The building itself reduces energy use and waste with high-albedo concrete for less energy consumption. It also uses a wastewater reclamation system and a grey water reclamation system that can hold one million liters. 

          Performing jobs

• Machine learning is a branch of AI where computers can be programmed to take data and make decisions, eliminating the need to code the machine to perform a job. There are opportunities to include small and medium-sized businesses in AI advancement through education, strategic investment, grants, task forces and advanced research initiatives. This education also helps ensure that personal and company data are not misused.

Waste management

         Waste control and resource optimization

• The concentration of low-cost sensors with integration and big data analysis appears to contribute to effective manufacturing systems. These innovations provide suppliers with new insights into how to optimize their manufacturing processes, sustainability and supply chain management for reduced prices and improved customer experience. Smart production practices also minimize waste and greenhouse gas pollution, whether by mistake or design.
• A number of IIoT technologies can help manufacturers use less energy and reduce production waste by allowing them to monitor multiple factors simultaneously including energy output, performance, maintenance needs and more.

Challenges in adopting Industry 4.0 for sustainability

A smart factory using Industry 4.0 technology is the ultimate goal for many manufacturers. After all, eco-conscious manufacturing has countless environmental and financial benefits including efficiency, waste reduction and less energy and natural resource consumption. 

However, the road to sustainable Industry 4.0 manufacturing has its obstacles such as lack of control over suppliers’ and partners’ commitment practices and trouble scaling. Many companies struggle to update their processes and operations. Below are some of the biggest challenges companies face as they adopt an Industry 4.0 strategy and work toward sustainability:

Smart equipment requirements

Smart equipment should be able to collect production information, provide compatible data interface and support generic communication protocol. Flexible manufacturing is a typical feature of a smart factory, but there are still many challenges in terms of production line such as dynamic scheduling and tight coupling between functions and devices.

The need for networks to be deeply integrated

The IIoT facilitates a deep integration of information and industrialization. Advanced IIoT technology is important for the implementation of the smart factory. However, standards have not yet been formed in the field of Industrial Wireless Sensor Networks (IWSNs). The standardization process must be promoted continuously. In the complicated electromagnetic environment, data transmission should meet the requirements of reliability and real-time equipment control.

Changing customer expectations

As Industry 4.0 trends emerge, customers expect manufacturers to adopt new technology accordingly. They want a seamless experience, more flexibility and less manual or administrative work. This translates to faster shipping times, more productive manufacturing plants and highly personalized customer service. Essentially, businesses need to leverage Industry 4.0 technology to transform how they interact with customers. Improving the customer experience can include using AI chatbots learning about customers’ behaviour and habits. It can also mean incorporating more robotics and data analysis on the factory floor to efficiently meet changing market demands and trends. 

Network security

Because of the access granted to large-scale devices, network security also becomes very important. Advancements in information technologies have produced significant progress in industrial wireless networks. These technologies include the Narrowband Internet of Things (NB-IoT), LTE-Advanced, 5G,and Third Generation Partnership Project (3GPP). Progress has provided new solutions for key IWSN issues, such as reliability, real-time performance, energy efficiency and security strategy.

A concrete plan to reduce scope emissions

According to a survey conducted by Fictiv and Dimensional Research, nearly 33% of manufacturers say a lack of knowledge about how to create a “concrete sustainability plan” is one of their biggest challenges. This is an especially significant issue for small and medium enterprises that want to create practical decarbonization strategies. These businesses can get started by: 

• Choosing more eco-friendly packaging. 
• Partnering with sustainable suppliers.
• Understanding their own emissions.
• Exploring zero-emission and low-carbon shipping options.

To develop an actionable plan, some manufacturers may also need consultants to help tackle complex supply chains and gather sufficient data. Autonomous, hybrid and electric vehicles—along with consolidated shipping—can also be a significant help on the path to net-zero. 

It all begins with manufacturers focusing on what they can change in terms of sustainability and supply chain management. Some manufacturers will need to shift their procurement approach to lessen their environmental impact. This is where nearshoring, reshoring, offshoring and friendshoring come into play. 

For example, nearshoring between the U.S. and Mexico means getting raw materials from a nearby, reliable and stable supplier. As a result, businesses produce less carbon emissions from transportation. They’re also less likely to be surprised by destabilizing events and supply chain disruptions. 

When choosing the best strategy be sure to consider:

• Shifts in the market.
• Spend analysis.
• Supplier options.
• Changes to consumer behaviour.

Is it time to rethink your sourcing strategy? Improve costs and reduce emissions with more advantageous procurement partnerships. Learn more