The author worked in the industrial automation industry in the early years, and later went to several cities and talked about the course of "Industrial Internet and Industrial Civilization History", so many people thought that I knew the industrial Internet very well (in fact, I am half a bucket of water). Someone asked me this morning, Industry 4.0 was awkward. I promised to tell him separately. Later, I thought it would be better to sort out the materials and ideas and share them with everyone, so I will talk to you about this mysterious Industry 4.0 today.
First declare that the author is just a porter of knowledge. I am not necessarily correct, but it is the result of digesting and understanding after reading a lot of materials. In fact, there is no standard answer for Industry 4.0, even the Germans themselves.
Look at the three concepts first:
Industry 1.0
Mechanization, marked by a steam engine, replaced the manpower with a steam-powered machine. From then on, the handicraft industry was separated from agriculture and officially evolved into industry.
Industry 2.0
Electrification, marked by the widespread use of electric power, replaces steam power with electric drive machines. From this part production and product assembly to achieve division of labor, the industry has entered the era of mass production.
Industry 3.0
Automation, marked by the application of PLC (Programmable Logic Controller) and PC, has not only taken over most of the physical labor of the human being, but also took over part of the mental work. The industrial production capacity has since surpassed the human consumption power. Humanity has entered an era of overcapacity.
These three definitions are very academic. You can rest assured that this is the most academic part of my full text. Later, I decided to tell the story of the old monk telling stories.
To understand Industry 4.0, we must first look at the current situation, we call it Industry 3.X, using the fashionable description of the novel, that is, in the middle and late 3.0, this state is called complete automation and partial informationization.
We have to start from the business model of the factory.
As a factory, there are only two purposes for producing products and then selling them. Therefore, in industrial enterprises, it is usually divided into two large departments, one is the production department, and the other is the business department. The former is managed by MES (Manufacturing Execution System), and the latter is managed by ERP (Management Information System).
What is the difference between these two systems? ERP is more inclined to the management of financial information, and MES is more inclined to control the production process. Simply put, ERP mainly tells you how many bottles a customer needs to produce, which day to place an order, and which day to buy goods, and MES is mainly responsible for monitoring and management. How each step and process of producing these bottles is achieved.
In many workshops in China's factories, connectivity between production equipment, production equipment and controllers has been basically achieved. In a more aggressive company, the entire plant has been connected through the Manufacturing Execution System (MES), and the business units are all connected through ERP.
Found a problem?
ERP and MES are actually not connected!
Therefore, when the ERP issues the production plan instruction to the MES, the MES has a deviation from the plan in the production process (such as equipment failure, raw material failure, etc.), and the MES will adjust according to the actual situation of the workshop. But ERP is not known! Therefore, it will continue to execute orders according to the original plan. Over time, the actual situation of the financial system and the factory will be very different.
As for the reasons for not being connected, the first two reasons are that ERP and MES development companies are usually two people, engaged in financial and production cooperation, not only do not understand each other's professional terms, chickens and ducks, and each other Can't see each other. In addition, the business department and the production department are usually operated separately in the company, and their respective leaders have their own favorite suppliers (for reasons you understand).
Of course, the wisdom of the people is infinite. They are categorically unequivocally waiting for the deviation of the two systems to become larger and larger. Since the system is not strong, and the labor is artificial, our workers have power. Therefore, the factory floor usually makes the MES adjustment items into a table and submits them to the business department, which is then manually adjusted by the business department in the ERP.
The problem of ERP and MES is only a microcosm of the system fault in the factory. In fact, there are many other systems in the factory, design, manufacturing, procurement, office, etc. These systems are all isolated islands of information. Knowing that the other person is doing what he is doing. One part has a special situation, and the other parts don't know. Only when the problem occurs, can it be returned, and all the systems will be changed one by one.
In a sentence, Lao Luo's hammer mobile phone is difficult to produce because the production personnel did not know the situation in real time at the time of design. Therefore, the actual production of the cow X design will result in a low yield and can only be returned to redesign. . In this way, every product has to be changed, so it takes one to two years for an industrial product to go from design to production.
Of course, this kind of thing is not the first day. In the past, because the product life cycle was very long in the industrial age, the author’s old owner, Siemens one type of inverter can be sold for 30 years, so that one or two years of research and development is on the line. Time is not so long, and the rest of the problems are based on manual communication. Although there are mistakes, they are all safe.
However, the terrible wolf is finally here.
These two wolves, one called overcapacity, one called the Internet.
Global overcapacity has led to more and more fierce competition. The past practice of selling a product for 30 years is no longer possible. You can't run fast, and some are fast. Lao Luo’s hammer mobile phone was only a few months in the evening, and it became an outdated product of the stinking street from a long-awaited explosion. The life cycle of the product was greatly shortened.
The arrival of the Internet era has shaken a big foundation in the industrial age and information asymmetry. In the industrial age, because manufacturers can't understand the needs of each customer at a low cost, they often use a one-size-fits-all approach, which combines the performance of demand to become a product.
For example, if you want a pair of shoes that fit your feet, the shoe factory can't know how big your feet are, so you can only measure the size of many people and divide the most concentrated size into 40, 41, 42 and so on. But if your feet are too fat or too thin, sorry, don't wait.
The Internet has changed this situation. People, people and manufacturers can connect at a low cost, so that everyone's personality needs are magnified, and people are more and more like personalized things. However, the demand for personalized things is not so large, which requires industrial enterprises to achieve rapid production in small batches.
These two wolves, forcing traditional industries to do one thing, the least thing that an industrial society does not want to do is fast, small batch, customized production.
At this time, we must first do some preparatory work, that is, the industry 3.0 must first evolve into 3.X, the so-called industrial 3.X, in fact, the ERP and MES and other information systems are completely opened, so that all the information islands of the factory are connected. . At this time, from complete automation and partial informationization, it has entered complete automation and complete informationization, which is the industrial 3.0 perfect stage.
Don't underestimate this process. Just this one, maybe China will take ten years or even longer to complete.
Well, the front is a real problem. After the 3.0 Grand Contest, we will start the sci-fi brain-burning journey, and we will finally hit Industry 4.0. In this process, 3.0 and complete automation and informatization have to start doing one thing, that is, getting married and having children.
This process, Germany called Industry 4.0, the United States called the Industrial Internet, our Ministry of Industry and Information Technology called the two-in-one fusion, the brain-net powder of the Internet of Things called it the Internet of Everything.
Here I want to say, all things, if you need to communicate, there is a problem, what language? Speak English, German, or Sichuanese?
What is the communication protocol, this is a key issue. You may say, why not use the Internet communication method, that is, the TC/PIP protocol. This is a technical problem, and you can't explain it to you. (In fact, my former half-bucket water automation engineer is not too big. understand). In short, the Internet communication method is still too slow, the accuracy is not enough, and the security is still not good. In industrial production, the requirements for speed, accuracy and safety are much higher than the requirements for downloading a movie.
Therefore, everything must be connected to a special communication protocol.
This is also the German industry 4.0, the US industrial Internet, and China's two-in-one fusion China manufacturing 2025, the core issue behind these fashionable terms, everyone is vying for this communication standard. The United States has the world's number one Internet, so Americans want to reduce the dimension from the information layer to the automation layer. Germany's machinery manufacturing industry is the strongest, so he hopes to upgrade from the automation layer to the information layer. China, manufacturing first Big country, the second strongest Internet country, so both sides do not want to follow, and intend to create an Internet +, also known as China manufacturing 2025.
According to the habit of comprehending novels, each realm must be divided into a small realm to highlight differences and arrogance. According to this method, I divide Industry 4.0 into six heavens.
Industry 4.0 first day, intelligent production.
As we said before, production equipment and management information systems are also connected, and devices and information systems are also connected. Do you feel that there are still shortcomings? That's right, the raw materials and production equipment produced are not connected yet.
At this time, we need a thing called RFID, RFID technology. Estimated that you do not understand, in simple terms, this thing is equivalent to a two-dimensional code, you can bring some information, he is more than the two-dimensional code fork, he can wirelessly communicate.
I still describe a scene. In Pepsi's production workshop, there are three bottles in the production line. Each bottle comes with a QR code, which records that it is customized for Zhang San, Li Si and Wang Er Mazi. Cola.
When the first bottle went to the filling station, the wireless control of the two-dimensional code was used to tell the controller of the central control room, saying that Zhang San likes to be sweeter and put more sugar, then the controller tells the filling robot, "Add two Pucker sugar!" (Zhang Sanzhen unlucky...).
The second bottle came over and said that Li Si is diabetic. Don't want sugar. The controller tells the robot. "This product doesn't need sugar!"
The third bottle came over and said that Wang Ermazi wanted Fanta, and the control told the cola's manipulator, "You will have a break," and then told the teacher of Guan Fenda, "You go!"
I saw it, multi-variety, small batch, custom production, every cola from the moment you place an order online, he is customized for you, all his characteristics are in line with your preferences.
This is smart production.
Industry 4.0 second heaven, smart products.
The production process is intelligent, so the industrial products as finished products can also be intelligent. It is not difficult to understand. What smart bracelets, smart bicycles, smart running shoes and other intelligent hardware you see are all this idea. It is to use the product as a data collection end, continuously collect user data and upload it to the cloud to facilitate user management.
One of the core differences between Demei Industrial 4.0 and Industrial Internet is whether to do smart factories first, or to engage in smart products first. Germany wants the former and the United States wants the latter. As for China, we will add it, or add this thing, and it will be added.
Industry 4.0 third day, production service.
As I said earlier, smart products will continuously collect user data and status and upload it to the vendor, which makes a new business model possible and charges the service. When I was at Siemens many years ago, Siemens proposed to charge for the service. At the time, I thought it was the stupid & TImes that Germany had come up with in mind. It was decided, but now I understand that it was started for Industry 4.0 a few years ago. The production service is laid out. What is your impression of Siemens? refrigerator? You are confused, Siemens has quietly acquired a number of well-known software companies in recent years, becoming the second largest software company in Europe after SAP.
What is this service? For example, Siemens produces a high-speed traction motor. In the past, it sold a motor directly. Now, this motor will continuously send data back to the Siemens factory during operation, so Siemens knows that your motor is running now. The situation, and when it is necessary to overhaul. How did high-speed rail manufacturers do it in the past? One-size-fits-all, set a time, until time, no matter whether it should be repaired or not, we have no difference in car maintenance. Now Siemens can tell you when you need to repair when you need to be cured, you want to know, sorry, give money.
For another example, after the smart product is realized, each car will continuously collect the surrounding data to determine its own driving route. The entire transportation system will be fully serviced. No one needs to buy another car. One day, maybe Driving can be a serious violation because the equipment is intelligent and people are uncontrollable.
At this stage, all manufacturers will transform to service providers.
Industry 4.0 fourth heaven, cloud factory.
When the two integrations of the factory are further deepened, another new business model will be born, this is the cloud factory.
The equipment in the factory is now also smart, and they are constantly collecting their own data and uploading it to the industrial Internet. At this point we can see which factories are running at full capacity and which are free. Then, if there are idle factories, they can sell their own production capacity and produce for other people in need.
Why the Internet industry is developing so fast is because entrepreneurs only need to focus on product and model innovation, and don't need to buy a server by themselves, but rent the cloud service directly. At present, industrial entrepreneurs still have to continually struggle to find OEM OEMs or self-built factories, which greatly limits innovation in the industrial field. When the cloud factory was realized, I predicted that China's industrial sector would have a wave of innovation and entrepreneurship that was more than 100 times larger than the Internet. At that time, everything in this society would be profoundly changed.
Industry 4.0 fifth day, cross-border strike.
The Internet industry says daily to reduce the traditional industry, what Google millet Alibaba LeTV, but I tell you that when Industry 4.0 enters the fifth day, the cross-border attack of industrial enterprises will be a hundred times stronger than these Internet companies. This process will fundamentally shake the foundations of modern economics and management and reshape the entire business community.
For example, a manufacturer of watches, this watch is attached to your body every day, collecting all the data of your body, these data may not be useful for watch manufacturers, but for the insurance company is a vault, this time, watch manufacturers You can become the best insurance company by changing your mind.
When automation and informatization are deeply integrated, cross-border competition will become the norm and all business models will be reshaped.
Industry 4.0 is a great consummation, the Matrix.
The entire Industry 4.0 process is the process of continuous integration of automation and information, and the process of redefining the world with software.
In the future, the multiverse will become a reality in the virtual world, and a real world will correspond to countless virtual worlds. Changing the real world, the virtual world will change; changing the virtual world will change the real world. Everything is precisely controlled based on data. Most of human physical and mental labor will be replaced by machines and artificial intelligence, and all current economic principles will no longer be tried.
But there are some things that won't change, I believe.
Human love, responsibility, courage, longing for the future and freedom, and endless struggle.
Life is endless.
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