Industry 4.0: Transition from Automation to Cyber Physical System

Industry 4.0 makes possible the realization of a Smart Factory, based on specific features of flexibility and self-reconfiguration. Therefore, as we have seen there is a main technology that makes it possible, this is Cyber Physical System in production. CPPS is a system, which exploit incredible computational power given by AI and real-time data transfer at a velocity never seen before. The main difference between actual automation systems and CPSs is that the last one reduces dramatically the need of re-plan and re-actualize procedures and processes during time, given environment uncertainties.

Therefore, it is not simple as we can imagine, in fact we will see that companies and researches are facing a lot of challenges and threats in order to realize a solid, reliable, and easy to diffuse technology.

During this paragraph, we are going to study in deep differences and the passage from standard automation machines and advanced modularity systems based on CPS. The aim is to see this passage from an academic and practical point of view, because we are going to talk about of sophisticated technologies based on flexibility made possible by single interfaces that communicate and exchange data among them. Given the fact that, Cyber physical System in production is a new and revolutionary technology that is based on modularity system. Where modules communicate each other. Thus, result of primary importance give an overview of the architecture and a glossary of terms and features of the system in general. Going in deep to functionalities and results in the next paragraphs. We can start saying that the basis of Cyber Physical System in production are mainly three, without any rate of importance. Human capital, manufacturing plant as set of machines and parties, and the final products. All these three things work together, communicate and exchange information. Data created will be used by CPS in order to monitor and control procedures and processes in manufacturing and entire life of products in terms of reliability and satisfaction. The huge amount of data produced, it has to be translated in knowledge that will be used at different time and level inside organizations. From operations is possible to give important information for the management of resources in terms of available material resources and energy consumption. In addition, as we have seen Industry 4.0 expresses its potential if applied to companies network, these relations produce information that can be translated in new capabilities and skills for improve processes. Through the words above, we have represented the plan and execution of a system composed of others sub-systems that can be can be called modules, which communicate each other making up forms of relations of different types in terms of degree, and purpose.

Thus, studying a modular architecture we are going to analyze a set of modules which are absorbed by a series and not a single task. In addition, they are linked and communicate among them through different interfaces. Modules inside a Cyber Physical System are composed of three embedded and interconnected parties: machines that operate inside the factory, service platform application that monitor in real time the environment, and finally a virtual representation of reality. The service platform application is embedded of computing power, it is able to reproduce the reality in the virtual space, giving at the same time, communication and analytical capabilities to each parties inside the production plant. This is the revolution, modules communicate and reply to environmental changes alone without any need of reprogramming. These are the main features that a Smart Factory composed of CPS must have, self-organization and self-adaptation. Above, we have described a system which is able to last in the time. This a characteristic that we can call run-time adaptation, because factories in this way are able to react and anticipate in a positive manner to changes. The last one can be referred to a series of things that are inside and outside the control of companies. Think about changes of products parties in terms of both material design or computational capabilities, way of working inside the production plant, thus a revolution inside the structure, finally a dramatically change of customers request due by preferences or law impositions. These are threats that today companies are facing, and with a modular and self-adapted system this is possible. Thus, we are going to list the most important features, that a reconfigurable factory embedded of the Cyber Physical System technology present. They are different and all presents the characteristic of self-reconfiguration.

First of all, in terms of flexibility the system presents the capacity to change plan and execution of the production process in terms of products type and not only the single product. In case of changes in the volume of market demand the system is always ready to react and manage material resources and machines. The system is composed of modules, which will be used at different rates second the necessity of the case. In case, new modules will be acquired such as new machines result of primary necessity that these will be integrated in few time in order to be immediately available to work. Finally, the last feature but probably the most important is analytical capacities in order to react to disturbances.

Keeping in mind the features and capabilities of a Cyber Physical System in production, now it is possible to introduce a comparison between classical automated solutions and CPPSs in different terms.

• Starting from the concept of module is possible to analyze the number, aim and how much is larger its action space. Thus we can observe structural architecture of modules of different complexity in base of how much is larger its final actuation scope.
• Result of primary importance in a system composed of modules the way of interaction among them. In fact, setting specific relations interfaces is possible to select a finite or infinite way of communication and the rate of autonomy among modules.
• Cyber Physical Systems present different rate of autonomy, feasibility and complexity. In fact, during the design of the system is possible to provide a different rate of autonomy, and interaction interfaces to modules, in order to self-organize the system. In any case, it will result totally different from classical automation solutions where there is not margin of self-organization. Therefore, we will see level of autonomy that are not yet possible to reach with existing technologies and regulations.
• Finally, as we said before existing technologies are not always able to support CPS in implementation and execution of a modular system. Therefore, result of primary importance seek and find the best possible supporting technologies for digitization and intelligent processes.

Different results for different aims

In the paragraph above, we have seen in brief the features of a CPPS system. Now we want to give some information about conventional automated solutions, in order to make a comparison between the two systems, and how to pass from a system to the other. Starting from the conventional automated solutions, we can see in all cases a profuse commitment in the design phase. This can be considered as the part that take more time and effort, even more the phase of machines and plant installation. The design and thus the realization of these systems are based on hierarchical relations among parties. It foresees a vertical monitor and control, without any kind of autonomy and horizontal communication among parties. Those solutions are not based on reconfigurability of the system, on the contrary they are based on customized solutions, which are supplied by specialized supplier. In case of need of changes inside the structure, those solutions suffer the problem of reprogramming and so, losing time and money. Automated solutions result production methods that are able to exploit its efficiency at maximum rate during stable conditions. In this kind of automated solution there are controllers along the production line, but it is not generalized as in CPPS through service platform applications and intelligent modules. In fact, in case of problems in production process can happen that large parts of the facility remain isolated and have to stop the work that they are doing. Thus, leaps to the eyes the lack of flexibility, capabilities of reconfigurability and convertibility. During the time has been considered reprogramming existing facilities as one of the most important feature of an automated system, in case of revolutionary changes and thus, new adaptations. But, reconfigure means stop the production process, loosing time, possible profits and market field satisfied in those moments by other companies or competitors.

Result of primary importance change the main pillar from reprogramming to reconfigurability or flexible system that permit self-organization and self-adaptation. Production systems based on CPS, are programmed in order to be flexible. Through, their main feature, modular systems are able to manage a lot of products families. Customization of products is one of the main objective of Industry 4.0 and CPS permits it to a large series of products reducing near to zero the time needed to program a machine. As we can imagine flexible manufacturing systems, until now through conventional automated system do not reach an acceptable level in terms of productivity, production time and costs. In fact, in order to have a certain rate of reliability, those systems require dedicated solution in order to manage a huge amount of products and different families at the same time without stuck the production process. To the other side through CPS, customization is not yet a mirage.

Scholars and even companies retain conventional automated solution easier to monitor and analyzed. Because all is structured secondo a hierarchical architecture, result quite simple to analyze cause and effects such systems. We can synthetizing saying that all single movement inside the factory can be foresee, because there will not be any change in way of working without any specific and declared plan. Therefore, the same cannot be said for Cyber Physical Systems in production as a whole of modules called CPPMs. It is not present a hierarchical and vertical architecture, rather parties of the manufacturing process are organized second a value added criteria. This criteria permits to a modularity system, where each module can be redistributed inside the value added process, to accommodate some changes. From the characteristics described above we can see that conventional production systems are realized in order to exploit at maximum their profitability, justifying in this way their architecture that do nor foresee changes without reprogramming plans. While, modular systems with CPS in production are realized second value-added criteria, that in case of need modules and equipment can be reconfigured, in order to develop a flexible and responsive factory. Therefore, given the amazing capacities and solutions that CPS offers, today this technology remains anchored to single and customized application for single companies, without the possibility to apply it on large scale. Without this transition will be difficult to expand the number of companies and industry sectors interested to Industry 4.0.

In addition, without a large diffusion it will not possible to reach the benefits mentioned in the chapter before in terms of productivity, efficiency and employment. Result of primary importance the alignment between system’s structure and working way in order to pass from traditional automated factories to value added modular systems. Through the speech above, we do not want to say that CPS technology is not applicable on large scale, rather it needs to be fully analyzed and developed, in order to become a standard for the larger part possible of manufacturing firms. In order to reach this goal will be of primary importance develop the best modules interfaces, for monitoring and control, and find supporting technologies that fit CPSs solutions