The Change in the Traditional Paradigm of Production under the Influence of Industrial Revolution 4.0
Abstract
:1. Introduction
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- The first one, which took place in the second half of the 18th and the first half of the 19th century, whose basis was the use of a steam engine in production and transport;
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- The second one, which took place in the years 1870–1914 and which was based on a new source of power—electricity—and automatization, allowing the manufacture of standard goods on a production line;
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- The third one, called the digital revolution, which started in the 1980s and is still ongoing. The Internet—its “wonder child”—computers as well as information and communication technologies, including mobile phones, are fundamental devices changing not only the character of production processes but also every other area of societies’ functioning.
2. Literature Review
3. Method and Materials
4. Discussion
4.1. Features of a Smart Factory
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- Interoperability, i.e., integration of machines, sensors, and people understood in terms of their ability to communicate via the Internet of Things and to continually download data indispensable for real-time decision making;
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- Transparency regarding data downloaded from different sources (providing better visibility of the whole production process) and monitoring its course, which will allow machines and people to make better decisions;
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- Proactivity, i.e., the system’s ability to take action before the safety and continuity of production is compromised due to, e.g., machine malfunctions or supply shortages, based on historical and current data analysis;
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- Optimization resulting from minimized use of materials, energy, and workforce; shortened duration of operations and outages; increased precision and higher quality; as well as full or almost full recycling, meaning increased work efficiency and significantly lower production costs;
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- Flexibility that will allow the production system to adjust to the changes in the schedule and the type of goods manufactured quickly and with minimal external interference, because smart devices will be able to configure machinery and procure materials needed to realize, implement, and control a particular project by themselves;
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- Autonomy, i.e., the ability to make decisions regarding the course of the production process, monitoring its harmoniousness, elimination of anomalies, and quality control without or with minimal participation of people.
4.2. Smart Production Technologies and Their Advantages
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- Advanced robotics—devices able to function autonomously and to communicate among themselves and with people, equipped with artificial intelligence that allows them to learn from experience, i.e., to carry out recurrent production processes. They can be easily reconfigured, which enables flexible and quick reaction to changes in projects. Their use increases safety in the workplace. The physical interaction of employees with co-robots is possible without protective devices, which makes work easier and increases satisfaction. Robots and automatization shorten the production cycle, increase productivity and precision, and enable better use of the production area.
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- Automated guided vehicles—vehicles that do not require a driver, already being used to transport materials and raw materials from warehouses to the place of production, to ensure the repeatable movement of the materials in the production process, and to deliver the products to the warehouse. Their movements are precise: they slow down or speed up depending on the circumstances. Their use increases safety and eliminates the risk of damaging the product in transport, which is why they are particularly well suited to transport delicate products. Thanks to them, transport costs are lower and the flow of raw materials, other materials, and products smoother, on time, and failure free.
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- 3D printing, also called additive manufacturing or distributed manufacturing—automated production of three-dimensional objects based on a digital design or model. Controlled by the computer, the printer layer after layer adds the required material—metal powder, polymer, plastic, ceramic, glass, or an edible material (e.g., chocolate)—and a binding material. This technology enables the creation of products of complicated shapes in one go, which would not be possible using traditional methods. The products are more durable and resistant and precisely match the models. 3D printing is changing the paradigm of production by decentralizing it, i.e., moving the production process closer to the client. Products can be cheaply manufactured in mall series or even individually, which allows for mass customization and personalization. They can be created based on peer-to-peer communication between the manufacturer and the client, where the manufacturer directly delivers to them a model or a description of the desired product. The wide-spread use of this technology will result in an unprecedented diversification of products; development of innovativeness; more effective use of resources; shortening of the time needed to manufacture the final product based on the design delivered; as well as lowering of the cost of design, manufacture, distribution, and transport. The needs of the consumers will be better fulfilled, which will increase the sales and the income of the manufacturer.
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- Industrial Internet of Things—a virtual global network of unambiguously identified things and devices that can indirectly or directly gather, process, and exchange information using computer networks. This information, provided to them continuously and in real time, is used to increase the effectiveness of operations, helping to effectively manage and monitor the flow of raw materials, other materials, and products, as well as to remain informed about their status: dimensions, quality, expiry date, usage conditions, or location in the warehouse.
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- Big data analysis—gathering and processing large quantities of data and cloud-computing them in order to carry out smart production and manage supply chains. It allows not only autonomous forwarding of information about threats but also foreseeing and preventing them. The ecosystem of data is characterized by [27]:
- Volume—amount of generated and forwarded data;
- Diversity of form—text, image, video, and sound or their synthesis;
- Speed—the speed of generating and processing data;
- Authenticity of data quality and value—efficient management of a factory requires analyzing both visible and invisible data, such as the degree of wear of machines and devices.
- Connection (sensor and networks) refers to devices related to the processing of the data provided by an external service provider;
- Cloud (data and calculations) is a data-processing model provided by an external service provider;
- Cyber (model and memory) is a solution for data protection in mass storage and ensuring their cyber resistance;
- Content and context refer to facts, trends, and statistics and the relationship between them;
- Community (sharing and cooperating) means the data are generated from social media and made available by online platforms to authorized users;
- Personalization and value means the type of data is adjusted to diverse clients.
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- Nanotechnology—the manipulation of atoms and extremely small compounds (a nanometer is one-billionth of a meter) in order to create materials characterized by high effectiveness, lightness, extreme durability, adaptability, and recyclability. One example of such a material is graphene, 200 times harder than steel, stronger than diamond, and a million times thinner than a human hair [11]. Such materials can be used to make smart products, for instance, ones that remember their original shape or that react to the changes in external conditions, such as temperature, atmospheric pressure, humidity, light, magnetic field, voltage, or chemical compounds (dirt-resistant fabrics). Changes in products with nanoparticles can be repeatedly reversed and externally controlled, thanks to artificial intelligence devices installed in objects with nanomaterials. Nanomaterials will be useful in medicine, pharmacology, production of sensors, microprocessors, solar cells, nanotubes, nanowires, and cars that use less fuel and have cleaner exhaust emissions. In the future, the manufacturing of nanomaterials could be based on the principles of mechanic engineering combined with atomic specificity, that is, on non-biological molecular machines. Such production and its results will be completely different from traditional ones and will constitute an evolutionary variant of a smart factory.
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- Augmented reality, also called mixed reality—the multimedia generation of a virtual image of objects, spaces, and events, including elements of the real world and the fictional world. The images can be observed on computer screens that can be mini-sized and have a 3D format. This technology can be used, e.g., in the entertainment industry (computer games), medicine, marketing, training, weather forecasting, military and civilian aviation, astronautics, industrial production, and construction. Augmented reality is also called digital prototyping because it is extremely useful in designing machines, devices, cars, and various appliances as it makes it easier for engineers to design and configure complex products and verify the designs, eliminating the need to create physical models. The virtual augmented reality scenarios also serve to test new machines and devices as well as the production processes, not only in normal, but also in extreme and unusual conditions, and to reveal and gather hidden knowledge and locations of items in the warehouse and the factory. The whole life cycle of the product, from design to implementation to production, service, maintenance, distribution, and repairs in the client’s home, can be better monitored and rationalized using augmented reality, which as a consequence increases the value for the producer and the client.
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- Digital simulation of production—using special computer programs in the early stages of the production cycle in order to plan, implement, and test the production process [28], as well as to evaluate the process, the improvements and changes introduced, and the impact of the planned investments during the process. A digital simulation of production provides information that serves to optimize the production process and create its new model, for instance, by configuring new production lines or changing the existing ones, eliminating bottlenecks, shortening the time required to deliver materials and perform certain operations, and improving their synchronization. It is also the basis for implementing such production organizing techniques as Just-in-Time, Kanban, Lean Management, Total Quality Management, Six Sigma, and Demand-Guided Production. Smart simulation is based on integrating its different techniques with artificial intelligence, augmented reality, and 3D printing. It enables experimenting, comparing alternative solutions, validating them, and choosing the optimal variant. In comparison to traditional methods (calculation sheets, modeling, etc.), digital simulation using the aforementioned Industry 4.0 devices constitutes enormous progress because of time saving; precision; flexibility; low costs; and the ability to foresee disturbances in, outages of, and disruptions in the production cycle due to internal and external occurrences, as well as their elimination or limitation of their negative impact. This is a modern, holistic approach to the programing of the production process.
4.3. Factors Stimulating the Implementation of Intelligent Production
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- The conditions for designing and planning production processes are improved and the time shortened.
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- 3D printing eliminates the need to make prototypes.
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- Ergonomic machines facilitate cooperation with people and guarantee their safety.
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- Automation minimizes the physical effort and range of operations performed by people, thus limiting their required work input.
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- There is better use of space in production halls.
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- Just-in-time deliveries, rationalization of intra-factory transport routes, and autonomous retrieval of the product from the warehouse and its transport to its destination save time and ensure reliability and punctuality.
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- Transparency of the production cycle allows one to monitor and control it, to make the right decisions in real time, and to quickly react to unforeseen events.
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- There is better use of machines’ work time.
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- Bottlenecks and outages in production are eliminated.
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- Automation enables autonomous prediction of malfunctions, pre-emptive conservation, and exchange of parts.
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- Automation enables flexible adjustment to changes in the scale, scope, and type of production and problem-free automated reprograming of machines and devices.
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- Products are personalized and customized.
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- Production occurs close to the customers, and their participation in designing the products eliminates the risk of unsatisfactory production and lowers transport costs.
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- There is a decreased need for outsourcing and offshoring due to the cost of the workforce.
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- R&D development enables faster rotation and shorter lifespan of products; smart products can change their features according to external conditions.
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- It is possible to monitor the whole life cycle of products, from production to recycling.
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- It is possible to combine production and high-value services (hybrid products).
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- Materials, raw materials, and energy are used more economically; there is less waste; full recycling, and thus closed-cycle production, is possible, as is more eco-friendly production.
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- Optimization of production processes and use of modern materials enable higher quality of products.
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- Smaller, lighter, and more durable products (nanomaterials) are created.
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- The production cycle is shorter, and the products are delivered faster to the market.
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- There is better vertical and horizontal coordination of supply chains and value chains and full integration of internal operations and connections with partners.
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- There is more effective machine and device control by decentralized intelligence, with minimal participation of people.
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- The technological gap between competitors is eliminated.
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- Production costs are lower—it is estimated that design costs could be lowered by 25%, related to a reduction in the number/amount of company assets by 10%, better use of resources by 30%, optimization of material flow by 35%, a decreased number of machines and devices at workplaces by 40%, and a shorter production cycle by 30% [37].
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- Work efficiency is increased.
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- The return on investments is faster and higher.
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- Wages and profits are increased.
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- There is increased value for the client.
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- There is stimulation of research and development.
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- New ground-breaking digital models of production are created.
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- There is increased competitiveness among companies.
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- Many factories in various countries have closed or reduced their production, which has resulted in the disruption of supply chains or a drastic decrease in the size of their supply of materials and semi-finished products. According to the estimates of international organizations, such as the WTO and the UNCTAD, in 2020, world trade fell by a third and foreign direct investment by around 30–40% [39].
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- However, it should not be expected that there will be a radical reduction in the factors that increase the risk of global supply chains presented here [40,41,42], as this would cause, at this stage of implementing the invention of Industry 4.0, a significant increase in costs and, moreover, due to the lack of appropriate raw materials in highly developed countries, finished products will not be possible.
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- In the short term, companies will rather diversify their sources of supply, duplicate suppliers, and limit just-in-time deliveries, increasing their warehousing capacity. In the long run, technological progress and a decrease in the costs of related equipment allow forecasting a significant increase in insourcing.
4.4. Barriers and Threats Related to the New Production Paradigm
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- Technical and technological difficulties;
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- High capital expenditures;
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- Limited market availability of smart machines and devices, software, modern materials, and suitable technologies;
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- Lack of required skills and commitment on the part of management;
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- Traditionalism; unwillingness to make changes on the part of employees and unions;
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- Difficulties in finding appropriately highly qualified workers;
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- High costs of employee training;
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- Government regulations;
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- Segmentation of the labor market and deepening of social inequalities;
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- Layoffs and increased unemployment among poorly and averagely qualified employees;
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- Violation of consumer privacy due to acquiring information in order to customize products;
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- Security threat to the smart factory due to cyberattacks and data leaks;
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- Organizational barriers;
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- Lack of international norms and standards facilitating international integration of smart factories and value chains;
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- Problems with international protection of intellectual property;
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- Risk of unforeseen malfunctions of complicated cyber–physical systems.
5. Conclusions
Funding
Institutional Review Board Statement
Informed Consent Statement
Conflicts of Interest
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Rymarczyk, J. The Change in the Traditional Paradigm of Production under the Influence of Industrial Revolution 4.0. Businesses 2022, 2, 188-200. https://doi.org/10.3390/businesses2020013
Rymarczyk J. The Change in the Traditional Paradigm of Production under the Influence of Industrial Revolution 4.0. Businesses. 2022; 2(2):188-200. https://doi.org/10.3390/businesses2020013
Chicago/Turabian StyleRymarczyk, Jan. 2022. "The Change in the Traditional Paradigm of Production under the Influence of Industrial Revolution 4.0" Businesses 2, no. 2: 188-200. https://doi.org/10.3390/businesses2020013