From digital vision to real revolution
On April 1, 2011, the magazine “VDI Nachrichten” published an article entitled “Industry 4.0: With the Internet of Things on the Way to the 4th Industrial Revolution”. In it, the authors described a paradigm shift according to which intelligent products within so-called cyber-physical systems should in the future play an active role in their own manufacturing process via embedded sensors and actuators. Some 14 years have passed since then. The vision of Industry 4.0 is now on everyone's lips worldwide. However, in many cases there is still a considerable gap between the vision and the reality in industrial practice. And this gap seems to be all the larger in the holistic view the smaller the companies are.
From technical debt to digital necessity:
Why change is inevitable
One aspect of this reluctance is likely to be the so-called “technical debt”, which cannot be easily eliminated. This includes, above all, the great heterogeneity in mechatronic equipment and IT infrastructure. Often, there is also a lack of vertical networking between the workshop and all levels of a company, or the directly resulting lack of (central) data collection and (decentralized) usability of data from the process chain. Furthermore, in the past, manufacturing companies were seemingly able to meet their customers' requirements effortlessly, even without extensive digitization efforts. However, there are increasing signs that the vision of industrial digitization in CNC manufacturing has also overcome the turning point to a real revolution. This is true, among other things, for reasons of regulatory accountability, for example, for the carbon footprint of processes and products or for their traceability. In addition, more and more customers are demanding the horizontal integration of their suppliers into global value networks. Furthermore, the demonstrably calculable advantages of the digital and thus data-based optimizable process chain have been solidifying since the advent of artificial intelligence at the latest. Examples include:
- Increased efficiency: Industry 4.0 technologies enable higher productivity and shorter throughput times.
- Improved precision: Real-time monitoring and data-driven adjustments increase the quality of machining processes.
- Cost efficiency: Reduced downtime and optimized resource utilization reduce costs.
- Flexibility and customization: Rapid adaptation to changing customer requirements down to a batch size of one is possible.
- Sustainability: Efficiency gains and waste reduction promote sustainable manufacturing practices.
Step-by-step integration for digital success
Small and medium-sized CNC manufacturing companies in particular are faced with the challenge of implementing Industry 4.0 technologies as extensively as possible and integrating them smartly into their existing manufacturing structures. Rather than a hasty system changeover, however, a step-by-step integration is recommended. The key to success lies in balancing quickly realizable improvements with sustainable investments. It is recommended to start by networking individual key machines, implementing standardized interfaces such as OPC UA (UMATI) and using cloud-based solutions for initial data analysis. Even simple sensor retrofits and data acquisition systems can provide valuable insights into processes, while manufacturing platforms enable smaller companies to access modern technologies. At the same time, long-term modernization steps should be planned:
- Developing a holistic digitization strategy
- Gradual renewal of the machine park
- Development of a future-proof IT infrastructure
- Investing in further training and qualification
- Creation of new competence profiles for employees
- Promoting an open culture of innovation
Digital twins and AI: new dimensions in CNC manufacturing
Digital engagement is gaining additional motivation from the perspectives offered by digital twins of machines and processes in combination with artificial intelligence. Generative AI tools such as ChatGPT have opened up a window of fascinating possibilities here, which, given the momentum in this area, will become relevant sooner rather than later. The spectrum ranges from job pricing, detailed production planning, adaptive process monitoring and optimization to predictive maintenance and servicing. Even automatic CNC programming from CAD data no longer seems impossible.
Industry 4.0 on the trail of the CNC revolution
The introduction of Industrie 4.0 technologies in manufacturing shows great similarities to the early years of NC and CNC technology: the initial reluctance due to high investment costs, a lack of standards, a lack of experience and different levels of expertise is once again meeting the enormous potential of a technology that, if successfully integrated, can revolutionize manufacturing. Just as CNC technology ultimately became an indispensable standard in modern production, a similar path can now be assumed for Industry 4.0.
The advantages that are already visible today – increased efficiency, data-based process optimization, flexibility and sustainability – are similar in effect to the advantages that were initially discussed only in visionary terms in the early years of NC and CNC machines and later fully realized. The key to success then and now: a step-by-step, well-thought-out approach – start small, make initial successes quickly visible and implement a long-term, holistic digitization strategy. In this way, today's digital transformation will also develop into a resounding success, just as it did when conventional machining made the leap to CNC.