M ajor technology breakthroughs are no longer just the stuff of startups in places like Silicon Valley , Boston or The Research Triangle . Today , technological innovation is happening in every front office and shop floor , and the Industry 4.0 revolution is underway . So what is it ? Industry 4.0 can be described as the latest evolution of manufacturing technology , utilizing concepts such as systems integration , data collection and analysis , automation and robotics , and the Internet of Things ( IoT ).
Sound complicated ? Well , it doesn ’ t have to be . Simply put , Industry 4.0 describes technologies and processes that are helping manufacturers understand their operations better and leverage that information to increase productivity and efficiency .
“ With Industry 4.0 , we are seeing a shift that is transforming U . S . manufacturing ,” says Robert Scipione , Applications Engineer with the Michigan Manufacturing Technology Center ( The Center ). Scipione and The Center help manufacturers understand Industry 4.0 and how these evolving technologies can be applied in order to increase revenue and innovation .
“ Industry 4.0 provides levels of interconnectivity that empowers a business to make decisions in real time ,” he says . “ Ultimately , [ Industry 4.0 ] will enable manufacturers to become more flexible and react to market changes . With the ability to enable new processes , products and services , Industry 4.0 can increase innovation speed , and it is consumercentered , leading to faster design processes and closer interaction with customers .”
Using Automation to Increase Revenue and Attract Talent
Heidi and Bob Devroy , Owners of Richmondbased Prosper-Tech Machine and Tool , had a problem — they didn ’ t have enough people to meet customer demand , which is a challenge nearly all manufacturers and employers are experiencing . Finding skilled talent in a large labor market can be hard enough but , if you ’ re a small manufacturer in a small town , it ’ s not just difficult , it ’ s nearly impossible . The Devroys started Prosper-Tech in a town of about 6,000 people 14 years ago . Today , with 11 employees , they are using technology and Industry 4.0 technologies such as robots and automation to augment staffing challenges and help grow the business .
Their adoption of these new concepts came through a medical client opportunity which placed a significant strain on production .
“ It was hundreds of parts being machined . Instead of just one , or two , or three , it was hundreds ,” said Bob , who worked in the automotive industry
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before starting Prosper-Tech with his wife . The new opportunity meant they would have to run a third shift — which is easier said than done .
“ For our shop size , we would need three people working at night , which is not easy to accomplish ,” says Heidi .
I ’ m very conservative financially and don ’ t want to go under . But I also recognize that we have to keep progressing with the technology and take advantage of what it has to offer .
— Heidi Devroy , Co-Owner , Prosper-Tech Machine
The lack of talent to meet the company ’ s growth led to the Devroys investing in new equipment and a robot that could run continuously to take advantage of those “ lights out ” opportunities . It has worked out so well ; they are now considering adding more equipment to the robot . Despite the initial up-front investment , which Heidi admits was a major hurdle to get over , they ’ re already seeing the payoff .
Heidi sums up the decision : “ I ’ m very conservative financially and don ’ t want to go under . But I also recognize that we have to keep progressing with the technology and take advantage of what it has to offer .” Prosper-Tech has taken a “ grow-your-own ” approach to staffing by blending the knowledge of their experienced mold makers with the tech savviness of their machinist and mold maker apprentices . Research has shown that providing opportunities for professional development and to “ upskill ” through learning new technology is a major driver when cultivating new talent — and Prosper-Tech has crafted that approach well .
“ I think that the younger crowd thrives with technology . They migrate towards it . And I also think it makes it easier to sell the machine shop format as a career ,” Heidi adds . “ And it ’ s a service to them because ... they ’ re learning at a shop that has cutting-edge technology .”
To further encourage growth for their business and the industry as a whole , the Devroys planned to take apprentices to the 2020 International Manufacturing Technology Show ( IMTS ) but it was cancelled due to COVID-19 . They now plan on attending the 2022 IMTS to , “... let them experience it firsthand , and see the latest technology out there . Even though we may not be able to do it here , they at least know what ’ s there , and it helps their minds grasp what ’ s coming next ,” says Bob .
Prosper-Tech is one of the many manufacturers in Michigan that has taken a successful leap into Industry 4.0 and is a great example of how these