Industry 4.0 in Automotive Industry: Top Applications, Benefits, and Examples

Seamless move from fuel-efficient, powerful vehicles to the emerging electric-powered vehicles, the automotive industry is witnessing some path-breaking changes with the onset of Industry 4.0. One such remarkable development is the inclusion of Additive Manufacturing or 3D Printing.

Additive manufacturing is a cutting-edge and faster-growing technology that allows designers to work on and simplify rapid prototypes and complex designs, which otherwise would have been hard to achieve through legacy subtractive manufacturing processes. This newfound technology provides the automotive industry with designs and freedom to innovate, making the supply chain proficient. In addition, this is an efficient, optimized, and cost-effective way to enable testing, manufacturing, managing, and assembling automotive parts and components.

"Digital Twins" is a primary data-driven manufacturing concept, enabling manufacturers and enterprises to simulate products, building faster, cost-effective, and quality benchmarked products.

A digital twin is a virtual doppelganger of an entire vehicle in the automotive industry, replicating its software, mechanics, electrics, and physical characteristics. The digital twin is all-inclusive of real-time sensors, performance, inspection metrics, service history, configuration changes, warranty, and replacement data.

Cost pressure, high-strung competition, market volatility, and sudden disruption have been challenging for the automotive industry. Big Data and Analytics is a powerful tool that helps discover incredible possibilities. Analytics, when done right, can help in the advancement of the automotive industry in several ways. It effectively enhances vehicle security, increases uptime, decreases repair costs, and much more.

Artificial Intelligence uses data and algorithms to recreate human intelligence and smart thinking. It contributes to independent problem solving across different sectors. AI finds numerous applications across the automotive assembly and value chain.

Currently, AI is sought after and implemented in design thinking, automotive manufacturing, production, supply chain, and distribution. In addition, AI is used to create 'driver assistance' and 'driver risk assessment' systems, transforming and strengthening security in the transportation sector. AI is also gaining a stronghold in the aftermarket services such as predictive maintenance and insurance.

For decades, the automotive industry has been using robots in its production and assembly lines. This technology pushes the industry to be more efficient, accurate, and agile in the process. In addition, the use of robotic vision, spot and arc welding, painting, sealing and coating, internal logistics, and material repair and removal helps the workforce at large with the heavy work, reducing loss of workforce and speeding up production.

Auto manufacturers, businesses, sellers, and insurers are processing millions of transactions daily. While transactions are now mainly online, through banks, web or mobile, cybersecurity risks, lack of transparency, excessive documentation continue to prove irksome, getting in the way of productivity.

Blockchain technology has been a promising tool leading to stress-free and painless transactions. Blockchains are shielded from accidental data deletion or loss and easily integrate with the existing technological framework. Blockchain is a perfect immunity booster against fraud prevention and ensures process automation wherever required. A blockchain-based service always enhances your current system making everything better.

Redefining solutions aligned with the new automotive age, IIoT is bringing in advanced and connected car solutions, keeping innovation at an all-time high. Vehicle-to-Vehicle (V2V) applications, Advanced Driver-Assistance Systems (ADAS), Vehicle to Infrastructure (V2I) applications, in-vehicle infotainment systems, predictive maintenance solutions, navigation & telematics, and Vehicle to Everything (V2X) communication applications, IIoT has immense potential to design and innovate come of age automotive features.

Original Equipment Manufacturers (OEMs) in the auto industry are using Cloud Computing and Solutions to improve the quality and efficiency of production. From sales to aftermarket service, the technology introduces the concept of new connected vehicles across all categories. Automotive suppliers use cloud computing to maximize uptime, improve first-time quality and optimize productivity. In addition, dealers leverage cloud computing and cloud technologies to reach and engage potential in-market shoppers, monitor vehicle performance, and create a customer service experience. Thanks to the cloud, consumers today enjoy enhanced shopping experiences, timely service, and variety.

IT/OT convergence is one consolidated way to control industrial operations. It integrates the overall technology framework with the operational framework, the information technology (IT), the hardware, and software.

The convention siloed approach practiced by the factory workers is now challenging with PLCs, human-machine interfaces, industrial PCs, and automation controllers installed in every touchpoint. Incorporating modern capabilities in the legacy system proves difficult and might lead to disparity in management systems.To avoid interoperability issues and production inefficiency, a seamless marriage between IT-OT frameworks is necessary to produce that perfect vehicle.

What we have today is a supercomputer on wheels. The modern car is an automated automobile with lots of sensors and cameras that generate a wealth of data. With the help of Intelligent Automation, data and technology are brought together for collection, manipulation, analysis, and dissemination. Robotic process automation is an absolute necessity on the automobile shop floor, from welding to assembly to painting, and this technology manages everything. Even car financing and distribution have been simplified through automation.