| |February 20209ROI will be seen over a period of two years and companies who have invested in early 2016 have seen these benefits. By 2020, it is expected that there will be 100 percent of Automobile & manufacturing sectors highly digitized.It has been proven that there will be about 5-30 percent of reduction on Repair, rework, scrap, service calls, warranty claims, write-off from obsolete finished goods.Current challenges in shop-floor are:· Timely unavailability of data for fault diagnosis· Most of the data are in non-digital format & analysis is user dependent with expertise· CNC machines have capability to display data, but it is humanly impossible to analyze data manually at each machine.· PLC's have not been used to provide data and few legacy systems with serial ports have limitations· Other non-conventional machines like Cranes, compressors, induction motors, Generators, pumps etc., are in-capable of providing data.Digital transformation will give a clear visibility to CXO level or senior management on the actual happenings on the shop floor. There will systems introduced like Sensors, HMI, PLC, SCADA, Device control systems and other engineering systems which will fetch the data. This will be processed from the huge data accumulated, later analyzed & appropriate data will be integrated with ERP, MIS systems. Decisions can be taken depending on patterns or signatures of data which can be automated called as Artificial intelligence (AI). Systems or machines can correct themselves when there is any kind of failure expected or alert prior to any major failures.Further, this has enable introduction of AR/VR devices which can showcase current servo temperature, load on bearings, battery condition and Absolute position & vibration of spindle or any such parameters. Just looking at a machine with goggles one would be able to know health of the machine & its characteristics. Next vision would be Digital twin where one would be able to operate the machine or experience the machines using AR/VR and tweak system virtually to find out improved end results.To summarize, Industry 4.0 shall give following benefits· Reduce inspection and maintenance costs· Reduce failure related repair or replacement costs· Reduced revenue losses due to lost in plant production· Enables the condition based monitoring· Deferred capital costs due to load growth or equipment age and condition· Improved confidence and security for dynamic over loading performance· Detects incipient faults and assist in preventing failures and unplanned outages· Provides monitoring and diagnostic for all vital parts by integrating. Digital transformation will give a clear visibility to CXO level or senior management on the actual happenings on the shop floorMallikarjuna Sarma,Chief Digital Officer
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