Industry 4.0: the transformation of quality management in manufacturing

What is industrie 4.0?

The industrial revolution is somewhat familiar to most from history books. However, did you know we are still in the midst of it? Some nuance is necessary here: we are indeed in the fourth phase of the process. And we have made significant progress since the first phase! The term Industry 4.0 was first used in 2011 when the German government introduced a new industrial policy, 'Industry 4.0'. The concept has since become indispensable in manufacturing.

The fourth industrial revolution is driven by various distinctive elements, including networks, data, and smart technologies for analysis and predictions based on machine learning. Within Industry 4.0, all processes in the chain are interconnected and capable of communication. The focus is on integrating and automating processes in the supply chain, with the primary goal always being continuous improvement in customer orientation and personalization.

From Industry 4.0 to Quality 4.0?

It's widely recognized that quality management plays an increasingly important and significant role in the performance of companies within the manufacturing industry. However, it goes a bit further than just the importance of quality management: with the advent of Industry 4.0 and the introduction of new techniques and systems, the face of quality management is also changing. Quality controls are increasingly automated, data is collected and analyzed in 'real-time', and processes are continuously improved through new insights. We have moved beyond reacting to now becoming proficient in anticipating or forward-thinking. We are developing our predictive capabilities with the help of elements characteristic of Industry 4.0. The standards for quality and production are rapidly increasing due to these developments. To keep the quality of processes and production, and their management, in sync with the developments pushed by Industry 4.0, we have also entered a new phase in quality management: Quality 4.0.

What does Industry 4.0 really mean?

Now that we understand the origins and focus of the terms Industry 4.0 and Quality 4.0, the big question remains: what can we do with it, and what are the advantages and potential disadvantages of this new phase? One of the most important developments, which is of great value to Quality 4.0, is the integration of the supply chain, aiming for an 'ideal situation' where the systems of manufacturers, suppliers, and customers are interconnected. The major advantage is that all systems can communicate with each other, making it easier to seamlessly align different processes. To pursue this ideal situation, a considerable number of new techniques and systems have been developed in recent years.

Smart Industry

The advent of IoT, the Internet of Things, also known as 'smart industry', enables simple devices and machines to communicate with each other. Thus, 'normal' devices receive a technological upgrade through the addition of sensors and actuators, enabling them to recognize and communicate information to other devices or systems. For example, imagine a supermarket refrigerator signaling the replenishment system when it's almost empty to restock. This is a simple example, but similar processes can occur on a much larger scale, such as entire factories communicating with each other.

Artificial Intelligence (AI)

Perhaps the most significant development of the last two years is the widespread introduction of artificial intelligence, or AI – in manufacturing, but also in many other sectors. AI has taken a huge leap forward, especially with the introduction of popular AI tools like ChatGPT and Midjourney, and is seen as the missing piece that was lacking in the fourth industrial revolution. AI goes a step further than the Internet of Things. Within IoT, separate elements, for example in the supply chain, are capable of communicating. With AI, these elements can not only communicate but also predict developments. Machines and devices are taught to recognize certain patterns, developing a predictive capability and eventually making autonomous decisions. This helps identify and correct errors in production processes and allows devices to indicate when maintenance is needed, preventing production disruptions due to overdue maintenance.

Cloud computing

A significant development for quality management is the advent of cloud computing. Cloud computing allows companies to securely store and access (real-time) data. This is one of the most crucial steps taken in the last decade in quality management: the ability to access and modify real-time data anytime and anywhere.

What are the advantages of Quality 4.0?

Quality management combined with Industry 4.0 – what will it cost my company? This is a valid question, as making all equipment Industry 4.0 proof requires considerable modifications. However, the benefits, which are indeed significant, are compelling: improved business performance, streamlined processes, higher quality on multiple fronts, and increased certainty.

Improvement of performance

By integrating the aforementioned systems into your company, you create a huge potential for growth in your company's performance. An additional benefit is that, influenced by the developments initiated by Industry 4.0, quality management becomes more effective, faster, and more efficient, significantly reducing failure costs – costs incurred from preventable errors in the production process.

When the quality management system fully functions based on the learning capacity of systems in the supply chain, ensuring data accuracy, you as a quality manager can shift your focus. What will you do with the extra time afforded to you as all microprocesses are handled and regulated by systems fully operating on AI?