{"id":10973,"date":"2019-06-23T12:43:35","date_gmt":"2019-06-23T15:43:35","guid":{"rendered":"https:\/\/industriall.ai\/blog\/?p=10973"},"modified":"2022-01-04T13:23:16","modified_gmt":"2022-01-04T16:23:16","slug":"importance-simulation-industry-4-0","status":"publish","type":"post","link":"https:\/\/industriall.ai\/blog\/importance-simulation-industry-4-0","title":{"rendered":"The Importance of Simulation in Industry 4.0"},"content":{"rendered":"\n

We are\nliving the 4th<\/sup> Industrial Revolution (or Industry 4.0), which is\nonce again changing the industrial environment. By using technology tools like system\nintegration<\/a><\/strong>, big data, augmented\nreality<\/a><\/strong>, internet\nof things<\/a><\/strong> and simulation, industries are much more efficient and\nproductive, to the point of improving their processes, product quality and\ncustomer service.<\/p>\n\n\n\n

In that\nsense, using simulations is one of the strategies used to achieve better\nresults, and in this article you will understand how this pillar of Industry\n4.0 can be very strategic and bring benefits to industries.<\/p>\n\n\n\n

What is simulation?<\/h2>\n\n\n\n

Simulation\nin industries is related to virtually reproducing\nenvironments and processes that happen inside the factories<\/strong>. In this way,\nit is possible to bring the physical world closer to the virtual world to\nanalyze data, monitor results, and improve any processes that may fail.<\/p>\n\n\n\n

All of it\nhappens without causing problems to the production goals, nor causing waste in\nindustries, after all everything happens within computer systems.<\/p>\n\n\n\n

In many\ncases, when making important business decisions, industry managers end up\ndelaying or even canceling projects because of lack of understanding about the\nrequired investments, the proposed optimizations, or the financial return that\nhas been calculated.<\/p>\n\n\n\n

The Importance of Testing<\/h3>\n\n\n\n

Because of\nthat, the use of simulation software has grown and is a great tool for learning\nand performing experiments. In these\nenvironments it is easy to analyze data and errors are allowed<\/strong>, different\nfrom what happens in the real production process, in which small problems or\nerrors can cause great damage or cause quality issues in the products.<\/p>\n\n\n\n

Thus, from\nthe analysis performed by the software and the employees involved in the\nproject, it is possible to identify where the most important bottlenecks are,\nand what actions should be taken to solve them.<\/p>\n\n\n\n

Similar to\nother pillars of Industry 4.0, data is essential for a successful simulation.\nThis is why it is important that basic aspects such as processes, data\norganization, reliable storage of information and constant updating are working\nwell.<\/p>\n\n\n\n

Otherwise,\nit will not be possible to create a copy of the process to be simulated, which\ncan generate errors in the reports.<\/p>\n\n\n\n

The similarities of Simulation and Lean Manufacturing<\/h2>\n\n\n\n

In an industrial\nenvironment that uses Lean Manufacturing, the objectives are to achieve greater\nefficiency in the following aspects:<\/p>\n\n\n\n

\u2022 Stocks;<\/p>\n\n\n\n

\u2022 Deadlines;<\/p>\n\n\n\n

\u2022 Customer\nService;<\/p>\n\n\n\n

\u2022 Quality.<\/p>\n\n\n\n

In order to\nachieve these goals, the use of simulation is very interesting. This is because\nwhen performing simulations in complex systems associated with the other\npillars of Industry 4.0, managers can\nunderstand better about the processes<\/strong>, bottlenecks and important aspects of\nLean Manufacturing like lead time and takt time.<\/p>\n\n\n\n

As part of\nLean methodology, factories have maps of its internal flows and efficiently use\navailable resources. Having these processes already in progress makes it much\neasier to use simulations to further improve aspects such as people, time and\nmoney in the factory.<\/p>\n\n\n\n

Just like\nin Lean projects, simulations take place following the same steps: definition,\ntesting, evaluation, improvement, implementation and monitoring.<\/p>\n\n\n\n

Understanding more about each step:<\/h3>\n\n\n\n

1. DEFINITION:\nThe first step is to define the problem to be solved and the desired result.\nFor this to happen, variables, people involved and requirements are also\ndefined.<\/p>\n\n\n\n

2. EVALUATION:\nThen it is time to start using the simulation tool, always paying attention to\nthe use of reliable data so that the generated reports are also valid.<\/p>\n\n\n\n

3. IMPROVEMENT:\nThe processes identified for the simulation can always be improved, from\ninternal feedbacks or inputs that come from studies or conversations with external\nstakeholders of your industry.<\/p>\n\n\n\n

4.\nIMPLEMENTATION: This is the time to use the developed model and check if the\nresults are being confirmed according to the simulation.<\/p>\n\n\n\n

5.\nMONITORING: Monitoring the results is essential, because as simulations happen\nbased on data, it is important to observe the reports as well.<\/p>\n\n\n\n

Thus, when\ncombining simulation with Lean Manufacturing, there is growth and sustainability\nin industries, improving the key performance indicators.<\/p>\n\n\n\n

Benefits of simulation in Industry 4.0<\/h2>\n\n\n\n

Simulation\nis one of the main pillars of Industry 4.0 and is related to other aspects such\nas artificial\nintelligence<\/a><\/strong>, system integration and use of data to evaluate problems\nand find solutions for the business.<\/p>\n\n\n\n

In\naddition, in order to better understand this trend, Gartner Consulting has showed\nthat the use of simulations<\/strong> (called\nDigital Twins) is one of the top 10\ntrends<\/strong> to be used and improved in the following years, in a survey in 2018.<\/p>\n\n\n\n

Considering\nthat Industry 4.0 counts on increasingly automated processes and without flexibility\nfor stops and tests, using Digital Twins in systems becomes very interesting.\nBy doing this it is possible for managers to make their decisions based on\nreliable results without the need for routine implementation.<\/p>\n\n\n\n

The main benefits observed by companies when using the\nsimulation are:<\/h3>\n\n\n\n

1. Communication between systems<\/h4>\n\n\n\n

When using\nthe Internet of Things (IoT), cross-system processing and communication between\nsystems become a reality, and it is used in simulations as well.<\/p>\n\n\n\n

Thus,\ndifferent sectors of a company that are affected by a problem can be evaluated at\nthe same time, resulting in an easier process for decision making.<\/p>\n\n\n\n

2. Reliable information<\/h4>\n\n\n\n

From the\ncreation of a Digital Twin (that is, an exact copy), all the systems and\nprocesses involved in the industrial plant are involved.<\/p>\n\n\n\n

With this,\nit is possible to gather high quality information so that it is evaluated as if\na real time test was being performed.<\/p>\n\n\n\n

3. Decentralization of decisions<\/h4>\n\n\n\n

While in\nnon-technological industrial plants people are the only responsible for\nstrategic decisions, in Industry 4.0 it is possible for computer systems to\nmake certain decisions.<\/p>\n\n\n\n

When caring\nout a simulation the same happens, because according to the data and limits\ndefined before executing the simulation, the systems can identify failures or\nproblems and use the reports to outline possible solutions to solve them.<\/p>\n\n\n\n

4. Comparison of different solutions<\/h4>\n\n\n\n

When tests are\ndone in an industry, the variables need to be checked individually, making\nthese tests time-consuming or incomplete of not all the possibilities as\nassessed.<\/p>\n\n\n\n

Thus, one\nof the great advantages of the simulation is to quickly compare different\nvariables and solutions proposed by the system, in order to follow the best\npath at that moment.<\/p>\n\n\n\n

5. Assistance for employees<\/h4>\n\n\n\n

During a\nsimulation it is common that repetitive or dangerous processes are identified.<\/p>\n\n\n\n

By understanding\nwhich are the bottlenecks, managers can change the organization or order of\ntasks so that they happen more quickly and productively, while improving the\nworking conditions of the people involved.<\/p>\n\n\n\n

In the same\nway, it is possible to use autonomous robots that can perform these tasks with\ngreater ergonomics and lower risks, thus freeing operators of certain jobs.<\/p>\n\n\n\n

Conclusion<\/h2>\n\n\n\n

Considering\nall this, Industry 4.0 and its pillars present great innovations, increasing productivity,\nand reducing wastes in the industries.<\/p>\n\n\n\n

As a\nconsequence, the simulation pillar is essential to have evaluations and tests\nin factory\u2019s production routines without causing problems to it. In addition,\nby simulating new or improved processes, risk of loss is avoided and better\ndecisions can be made.<\/p>\n\n\n\n

Do you\nalready use computer simulations in your industry? Do you agree that this is\none of the most important pillars in Industry 4.0?<\/p>\n\n\n\n

Leave your\ncomment below and share your experience.<\/p>\n","protected":false},"excerpt":{"rendered":"

Simulation is one of the most important pillars of industry 4.0. Understand how to use this strategy in industries and what are the advantages of it.<\/p>\n","protected":false},"author":5,"featured_media":11012,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false},"categories":[82],"tags":[],"yoast_head":"\nThe Importance of Simulation in Industry 4.0 | Blog IndustriALL<\/title>\n<meta name=\"description\" content=\"Simulation is one of the most important pillars of industry 4.0. 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