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Service engineer checking digital pump control system in a plant.
4 min read

How do companies benefit from digitalisation in the era of Industry 4.0?

Digitalisation is the cornerstone of Industry 4.0. But what specific benefits do companies gain from it? Predictive maintenance is one of the key technologies of Industry 4.0. When applied correctly and efficiently, predictive maintenance offers numerous benefits. Find out more here.

Digitalisation is the cornerstone of Industry 4.0. But what specific benefits do companies gain from it? Predictive maintenance is one of the key technologies of Industry 4.0. When applied correctly and efficiently, predictive maintenance offers numerous benefits. Find out more here.

After the first Industrial Revolution (c. 1800), the second (c. 1900) and the third (c. 1970), we now find ourselves in the middle of the fourth, also known as Industry 4.0. These four Industrial Revolutions have a common denominator: an increasing degree of automation. Whereas the development that played a decisive role in defining the new era in around 1800 was the first machines for mass production, in around 1900 the introduction of electricity as a source of motive power and, in around 1970, automation through electronics and IT, today it is the internet.

From precise real-time logistics through self-regulating production and predictive maintenance to efficient algorithm-based quality assurance: the many benefits that companies reap from digitalisation in the era of Industry 4.0 arise, above all, through the use of data generated via the Internet of Things (IoT).

For the latest generation of sensors and software can do more than just accurately model in real time all of the processes within a company and along the entire supply chain. Smart algorithms, big data applications and artificial intelligence are additionally capable of recognising certain patterns in the collected data and using them to make predictions about conditions and trends that can be expected in the future. In addition to this, the collected data can be stored centrally thanks to cloud-based solutions and made available across companies.

As a result of digitalisation, the linear supply chain is finally a thing of the past. Instead, the supply chain network and production are digitally linked together. This opens up many opportunities for companies to develop innovative, data-driven business models.

Pump automation: KSB provides support for digitalisation in industry

With its digital pump solutions and smart services, KSB supports its customers in making their systems fit for the digital future in the long term and thus in directly benefiting from immediate effects. With smart technologies such as KSB Guard that make systems instantly transparent, digital optimisation measures that allow considerable energy savings to be made throughout entire systems, or system-based processes for procurement planning. Feel free to ask us!

Industry 4.0: benefits of digitalisation simply presented

We have compiled the main benefits that companies can derive from digitalisation in the following infographics – along with the added value predicted in various areas.
Die verschiedenen Vorteile der Digitalisierung in einer grafischen Übersicht

Overview of benefits of digitalisation (source)

Benefits of digitalisation

Prognosis
  • Predictive quality
  • Prediction of manufacturing dates
  • Predictive maintenance
  • Calculation of material range of coverage

Analysis
  • Analyses and reports
  • Key performance indicators (KPIs)
  • Long-term analyses
  • Self-service analytics
  • Machine learning based on big data

Planning
  • Sequence planning of orders and operations
  • Resource allocation and work calendars
  • Personnel deployment scheduling
  • Operations scheduling and quality planning
  • Planning of material and energy use

Execution
  • Production control
  • Monitoring of process quality
  • Process interlocking
  • Online monitoring
  • Early detection of deviations
Grafische Darstellung der der zu erwarteten Werte bei der Implementierung digitaler Fertigungstechnologien.

Figures expected from implementation of digital manufacturing technologies (source)

Resources / process –> 3 - 5% increase in production
Availability –> 30 - 50% less downtime
Factories –> 45 - 55% more productivity through better knowledge management
Stock-keeping –> 20 - 50% lower warehousing costs
Quality –> 10 - 20% lower quality costs
Supply and demand –> 85% increase in predictive accuracy
Market readiness –> 20 - 50% shorter time to market
Service –> 10 - 40% lower maintenance costs

Used products

KSB Guard

KSB Guard
Documents

The smart and comprehensive monitoring service for pumps and other rotating machinery, available 24/7 and also for non-KSB pumps. Benefit from predictive maintenance with KSB: comprehensive transparency, increased availability, enhanced operating reliability and efficient operation (of fixed-speed pumps). Important operating data such as vibrations, temperature, operating hours and load condition (of fixed-speed pumps) can be accessed via KSB Guard, anytime and from anywhere. In addition, deviations from normal operation trigger immediate notifications via the KSB Guard web portal and/or app. The experts at the KSB Monitoring Centre also provide support in analysing causes.

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