The Fourth Industrial Revolution

The fourth industrial revolution, also known as Industry 4.0, marks a radical change in the way industries produce, distribute, and manage their operations. Unlike previous revolutions, which were driven by advances such as mechanisation, electrification, and computer automation, the fourth industrial revolution merges the physical, digital, and biological worlds, transforming industrial processes as well as everyday life.

The term Industry 4.0 has a dual meaning. On the one hand, it is synonymous with the fourth industrial revolution; on the other, it refers to the German government’s initiative to digitise its industry, an effort that has served as a model for many other economies seeking competitiveness in a globalised world. This concept implies not only technological but also organisational and cultural change that requires the merging of information technology (IT) and operational technology (OT), as well as professionals with the necessary skills.

According to the Boston Consulting Group, at the core of Industry 4.0 are nine technological pillars that are at the heart of this transformation: the Internet of Things (IoT), cloud computing, augmented reality, simulation and digital twins, 3D printing, advanced robotics, cybersecurity and blockchain, big data and artificial intelligence, and vertical and horizontal integration. The implementation of these technologies represents an opportunity for companies to increase their efficiency, flexibility, and customisation, enabling them to respond to changing market demands.

Internet of Things (IoT)

The Internet of Things has transformed the industry by connecting devices and systems to provide real-time data that optimises processes and improves sustainability. The implementation of this technology makes it possible to measure energy consumption in real-time, reduce the carbon footprint and anticipate machinery failures, minimising breakdowns, and increasing productivity.

In addition, IoT improves industrial safety by continuously monitoring critical data and generating real-time alerts to hazards or failures, reducing workplace accidents. It also facilitates just-in-time production models by providing accurate information that matches manufacturing to demand and contributes to cost reduction through automation and operational optimisation.

Cloud Computing

Cloud computing provides flexible and scalable access to computational storage resources over the Internet. This enables the handling of large amounts of data generated by IoT devices and advanced analytics. In contrast, edge computing processes and stores data where it is generated, reducing latency and enabling fast responses, essential for real-time applications such as industrial automation.

Both tools can be combined in hybrid solutions as needed. One example is the field of artificial intelligence in neural network-based applications. Training of these can be done in the cloud to take advantage of their scalable power, while faster and lighter operational tasks can be executed locally at the edge, ensuring an optimal balance between performance and efficiency.

Extended Reality

Extended reality encompasses technologies such as augmented reality (AR), augmented virtuality (AV) and virtual reality (VR), which transform interaction with the digital and physical environment. AR superimposes virtual elements on the real world, allowing additional information to be displayed using devices such as smart glasses or mobile apps. AV combines predominantly virtual environments with real elements, while VR immerses the user in a completely artificial environment, isolating them from the physical world through immersive headsets or glasses.

The concept of the industrial metaverse, led by companies such as Siemens, extends this vision by integrating extended reality, along with technologies such as IoT, digital twins, cloud computing, and artificial intelligence, to simulate and optimise industrial operations in virtual environments. Although the commercial metaverse has suffered a decline, the industrial domain continues to explore its potential as a tool to improve efficiency and connectivity.

Simulation and Digital Twins

Simulation allows virtual models to be created to analyse and optimise products, processes, and services prior to their actual implementation. A key advance is the digital twin, a virtual replica of physical systems that uses real-time and historical data to predict scenarios and improve decision-making. Thanks to IoT and big data techniques, these models are constantly being validated, functioning as essential tools in Industry 4.0.

3D printing

3D printing is the creation of physical objects from digital designs with better material utilisation. This makes it easier to produce customised parts and rapid prototypes. Currently, 3D printing with metals is on the rise, enabling the creation of high-strength components for sectors such as aerospace and automotive. Moreover, its integration with other 4.0 technologies is transforming supply chains towards more agile and sustainable models.

Advanced Robotics

Advanced robotics includes autonomous and collaborative robots that work alongside humans safely and efficiently. Thanks to artificial intelligence and machine vision, these robots can adapt to complex tasks, such as assembly, internal transport, and packaging.

Collaborative robotics has great potential ahead and faces challenges such as the ability to handle heavy loads and perform tasks that require very high precision. Yet it is already an essential part of Industry 4.0, offering innovative solutions to improve flexibility, efficiency, and safety in the working environment.

Cybersecurity and Blockchain

Cybersecurity is one of the factors that is forcing down the barriers between IT and OT, since in cyber-physical systems a computer attack can have consequences in the physical world beyond the loss or hijacking of data.  Technologies such as blockchain enhance security by ensuring data integrity and traceability. This is a technology that allows data to be stored in a decentralised and secure manner, making it virtually impossible to falsify the information stored, as any attempt to alter it would require modifying all the blocks in the chain. This is an important advance for cybersecurity in some application areas due to its ability to improve data integrity, confidentiality, and availability, with traceability, auditing, and smart contract mechanisms.

Big data and Artificial Intelligence

Big data and artificial intelligence (AI) are two closely related technologies that are transforming the way in which information is processed and used in the digital age. Big data feeds AI algorithms with large volumes of data, while AI uses advanced tools to analyse and extract insights from this massive data. Their combination is revolutionising fields such as business process optimisation, healthcare, personalised treatment development, scientific research, and customer care, facilitating more informed and effective decisions.

Vertical and horizontal integration

In Industry 4.0, vertical integration connects the management, supervisory, and field layers through customer-supplier relationships, optimising the flow of information and resources along the entire production chain. This improves coordination between enterprise resource planning (ERP) systems, manufacturing execution systems (MES), and physical devices, enabling more efficient and flexible management.

Horizontal integration, on the other hand, promotes cooperation between companies and processes, creating collaborative networks through digital platforms and APIs. This drives interoperability and facilitates the delegation of tasks between partners, also optimising production and fostering innovation across the industry.

The fourth industrial revolution is redefining the industrial landscape by integrating advanced technologies that connect processes, optimise resources and foster collaboration. With pillars such as IoT, artificial intelligence, digital twins, and advanced robotics, Industry 4.0 is driving efficiency, flexibility and innovation in operations. This change not only increases competitiveness, but also lays the foundation for a more sustainable industry that is ready for the challenges of the futureta les capes de gestió, supervisió i camp mitjançant relacions client-proveïdor, optimitzant el flux d’informació i recursos al llarg de tota la cadena de producció. Això millora la coordinació entre sistemes enterprise resource plannig (ERP), manufacturing execution systems (MES) i dispositius físics, permetent una gestió més eficient i flexible., sinó que també assenta les bases per a una indústria més sostenible i preparada per als reptes del futur.