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Smart factory: Industrial 4.0 core carrier manufacturing upgrading road

the State Council officially issued the made in China 2025 plan. Made in China 2025 and industry 4.0 emphasize that the direction of intellectualization and informatization is basically consistent with the development strategy, and a new round of manufacturing reform is gradually coming

smart factory: the core carrier of industry 4.0 and the way to upgrade the manufacturing industry

smart factory, also known as digital factory (DF), refers to a new production organization mode that simulates, evaluates and optimizes the whole production process in a computer virtual environment based on the relevant data of the whole product life cycle, and further extends to the whole product life cycle. Digital factory mainly solves the gap between product design and product manufacturing, realizes the functions of design, manufacturing, assembly, logistics and other aspects in the product life cycle, reduces the uncertainty from design to production and manufacturing, compresses and advances the production and manufacturing process in the virtual environment, and can be evaluated and tested, so as to shorten the transformation time from product design to production, and improve the reliability and success rate of products. Compared with general factories, digital chemical plants emphasize the digitization of production plans, and a large number of computer-aided technologies, such as CAD, cam, CIM, etc., are relatively fixed from top to bottom

the basic assumption of smart factory is that the products manufactured are integrated with dynamic digital memory, sensing and communication capabilities, carrying all kinds of information required in the whole supply chain and life cycle; The production facilities integrated in the whole production value chain can realize self-organization and flexibly determine the production process according to the current situation. The smart factory will establish a digital enterprise platform to integrate the virtual environment and infrastructure through open interfaces, so as to form an information physical integration system (CPS), and the production automation system will be upgraded to a cyberphysicalproductionsystem (CPPS)

industry 4.0 will change from centralized control to decentralized enhanced control. In this mode, the traditional industry boundaries will disappear. 2. Tensile experiments will produce a variety of new areas of activity and forms of cooperation. The process of creating new value is changing, and the division of labor in the industrial chain will be reorganized, which will enable mankind to enter intelligent, green and urbanized production from automated production. Information physical fusion system (CPS) is a next-generation intelligent system integrating computing, communication and control. It is the unity of computing process and physical process. It includes ubiquitous system engineering such as environment awareness, embedded computing, network communication and network control, so that the physical system has the functions of computing, communication, precise control, remote cooperation and autonomy. CPS produced by the integration of intelligent network world and physical world is also called industrial IOT

from made in China to smart made in China, this is the great era of industry 4.0! IOT and its services are used in industrial processes, resulting in an innovative factory system, smart factory. Completely different from the traditional factory automation system, the intelligent factory adopts the service-oriented architecture, and the specific architecture is shown in the above figure. As can be seen from the figure, corresponding to the field level of traditional automation systems, smart factories use IOT technology; Corresponding to the control level, the smart factory adopts the CPPs information physical fusion production system; The corresponding monitoring and management level is connected to a safe, reliable and trusted cloud backbone, and the smart factory adopts services provided by service interconnection

smart factory: it will improve the long-term competitiveness of the manufacturing industry

interconnection is the only way to activate traditional industry and maintain the long-term competitiveness of manufacturing industry: compared with the previous three industrial revolutions, we believe that the biggest progress of industry 4.0 is to use interconnection to activate traditional industrial processes, so that factory equipment can speak and think, and realize three functions at the same time: to minimize the dependence of manufacturing industry on labor, to minimize the circulation cost, and to meet the personalized needs of users to the greatest extent. In the long run, in the era of industry 4.0, the investment in smart factories will be much higher than that in general industry, but the profitability of the project will also be significantly improved if multiple experiments are carried out on one plate. The larger the capital investment, the steeper the slope, that is, the higher the marginal return on investment. We believe that industry 4.0 will be the only way for the development of manufacturing industry in any economy and the largest wave of manufacturing industry in the world in the future

we believe that compared with the traditional manufacturing organization, the long-term competitiveness of industry 4.0 smart factory for the manufacturing industry is mainly reflected in three aspects: reducing the dependence on labor, reducing storage and logistics costs, and meeting the personalized needs of users

1) reduce the dependence of manufacturing on labor: another reason why Germany attaches importance to industry 4.0 is the shortage of labor caused by aging. The aging degree of German population ranks second in the world, second only to Japan. The number of young employees in many German manufacturing companies is decreasing, and there has been a shortage of skilled labor. And the labor cost in Germany is very high. The labor cost of a typical manufacturing enterprise accounts for 25% to 30%. For China, in the future, with the disappearance of the demographic dividend, the reduction of labor supply, the rise of labor costs and the decline of the employment willingness of the new generation of labor in the manufacturing industry, the international competitiveness of the manufacturing industry is facing great constraints. The highly networked and automated smart factory in the era of industry 4.0 can minimize the dependence of manufacturing on labor, reduce labor costs, and significantly enhance the long-term competitiveness of manufacturing

2) reduce logistics costs: intelligent logistics is the core component of industry 4.0 and the ultimate solution to reduce the logistics costs of social storage: protect the gravity weight suspension equipment in the intelligent factory framework of industry 4.0. Intelligent logistics storage is located at the back end and is the core link connecting the manufacturing end and the client. Automated logistics warehousing is a logistics activity that effectively plans, executes and controls the entry and exit, inventory, sorting, packaging, distribution and information of goods by using advanced scientific and technological means and equipment such as software technology, interconnection technology, automatic sorting technology, optical guide sorting, RFID, voice control technology and so on. Typical logistics and warehousing automation systems mainly include: automated three-dimensional warehousing system, automatic conveying system (including mobile robot system AGVS), automatic identification system and automatic sorting system, as well as other auxiliary systems of robot operation system. Compared with traditional logistics storage facilities, the advantages of automated logistics storage system are mainly reflected in the saving of labor cost, rent cost and management efficiency. We estimate that automated warehousing can save at least 70% of land and 80% of labor under the condition of ensuring the same storage capacity. The automatic storage system can maximize the distance. 4. Place 1 slide on the stage to improve the accuracy of storage management, as well as the processing speed of identification, sorting and incoming and outgoing goods, reduce the inventory turnover rate, and meet the needs of modern fast logistics such as e-commerce and fresh food distribution

3) meet the personalized needs of users: since entering the information age and the Internet age, the product life cycle has become shorter and shorter, the pace has become faster and faster, the requirements for resource utilization have become higher and higher, and the personalized needs of users have been released rapidly, resulting in the abandonment of the mode of mass production in the manufacturing industry and the increasing demand for flexible real-time dynamic response. Because of the increasing demand for personalization, when the conditions are met, the previous large-scale and replicated production methods to improve production efficiency and reduce product costs will also change. In the industrial 4.0 era, personalized products will be produced in high-efficiency batch mode. Personalization is synonymous with intensive cultivation and flexible creativity. Large scale once meant large-scale and repeated production. Intelligent manufacturing is a production method that integrates personalization and scale, which are contradictions in industrial production. Interconnection can make all links in the manufacturing chain closer and more efficient

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