Digitalisation 3.9: Making Industry 4.0 not just 0!😅🚀

Digitalisation 3.9: Making Industry 4.0 not just 0! 😅🚀

🤔 Imagine that your company has a fully integrated Industry 4.0 solution. Everything runs smoothly, everyone knows how to use the systems efficiently and all processes are optimised. A distant future? Not necessarily! But before it can become a reality, a clear strategy and concrete first steps are needed.

✅ If you’re wondering how to get started on this journey, this blog is for you. Let’s assume that there is an intermediate state – let’s call it 3.9 – that summarises the minimum steps that are essential for the successful implementation of Industry 4.0. Only with proper preparation can we avoid Industry 4.0 ending up as a big “0”! 😅

📊 Many companies see the future in Industry 4.0, as digitalisation promises more and better quality data. However, if the fundamental issues are not clarified in advance, this move can cause problems. In my experience, Industry 4.0 provides more data, but it often remains just numbers without real information. In addition, many companies are still unable to define and solve their problems accurately – so the full potential of Industry 4.0 is not being exploited.

📍 Many focus solely on production and only display data there. However, other key areas, such as logistics and maintenance, often ignore KPIs, which can have a significant impact on optimisation:

🔹 Directly: faster response time to failures, more efficient problem solving. 🔹 Indirectly: better maintenance planning by comparing targets and actual status.

⚠️ Industry 4.0 solutions are often introduced but not fully exploited because workers do not believe in them. More data without a clear structure only adds to the complexity. Therefore, not only data is needed, but also clear dashboards that show priorities (e.g. through Pareto or trend analysis).

“It wasn’t clear before that the team couldn’t solve the problems in the long term – but after Industry 4.0 it’s becoming clear because the numbers don’t lie.”

This is why it is crucial to prepare and support teams properly. Leaders also need to evolve, because the modern technological environment requires more effective, strategic leadership.

1. Organisational and process development basics

🏢 Industry 4.0 is not only a technological transformation, but also a cultural one. Before adopting new technologies, companies need to be clear:

📌 What organisational and process challenges do they face? 📌 How to make operations more efficient?📌 What new skills are needed?

It is essential that Industry 4.0 is built on a well-functioning management system that ensures:

• Holding regular meetings between the different departments.
• Clear definition of KPIs that can be monitored and analysed.
• Clear lines of responsibility so that everyone is clear about their role.
• Develop structured agendas to ensure effective collaboration.

These funds are essential for efficient daily, weekly and monthly operations that support the implementation of Industry 4.0.

2. Problem solving and education

📚 Successful digitalisation requires staff training and clear problem-solving strategies. Managers and teams need to understand:

✅ How to interpret the data? ✅ What decision-making processes are needed?✅ How can lean and agile approaches be integrated into digitalisation?

It is important that employees have the ability to recognise problems, articulate them accurately and communicate them to management.

👥 Communication from the bottom up ensures that problems are not hidden and that there is support at all levels to solve them. This avoids micromanagement and enables more effective decision-making.

3. Definition and interpretation of KPIs

📈 The success of Industry 4.0 depends on defining the right KPIs and interpreting them correctly. Important aspects:

🔸 Transparency – KPIs for all departments concerned. 🔸 Training – All teams need to understand the KPIs. 🔸 Visualisation – Rapid identification of trends for timely intervention.

📊 KPIs are not just metrics, they are tools to help you improve efficiency.

💡 Important considerations when implementing a KPI system:

• Link to the decision-making process so that KPIs can be used to take quick and effective action.
• Choosing relevant KPIs that truly reflect your business objectives.
• These are presented visually so that all stakeholders can easily interpret the results.

4. Data and information flow

🧠 Industry 4.0 becomes even more efficient when combined with artificial intelligence (AI). This requires:

💾 Access to data for all departments concerned. ⏳ Availability of real-time data. 👥 Clear definition of responsibilities. 📨 Establish fast and efficient communication channels.

📢 Data should not only be visible on the production lines! Logistics, maintenance and quality controlshould have access to the information.

🔗 It is important for effective data management:

• Real-time data collection and sharing for all stakeholders.
• Adequate visualisation tools (e.g. dashboards) to help immediate decision-making.
• Use AI to identify trends and anomalies, facilitating rapid response and preventive maintenance.

📊 The flow of information is key to the success of Industry 4.0! If the right people do not get the data in time, the impact of digitalisation will be minimal.

Summary

Digitalisation 3.9 is the foundation for a successful Industry 4.0 transformation. Digitalisation is not an end in itself, but a strategic process that requires preparation. Companies need to optimise their structures, develop a clear data strategy and provide targeted training for managers. Only then can the full benefits of technology be realised.

Data alone is not enough – it must be interpreted correctly and used in a meaningful way. Proper preparation improves not only the quantity of data, but also its quality – and thus the real added value for the company.

🛑 Do not start Industry 4.0 without proper preparation! 📊 Getting the KPIs and data right is key.

🏆 Digitalisation is not a technology, but a strategic process.

Do you have questions to help us successfully prepare for Industry 4.0? Let’s talk about it! 😊

Attila Jezsó

Got a question? Contact us and together we will put together a tailor-made development package. We’ll even support you on the spot with consultants and coaches to make the change a success!

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