Industry 4.0 is a concept that defines the introduction of new business models, the digitisation of products and services as well as the implementation of new technical and organisational solutions in companies, integrating their value chain.
The implementation of new smart solutions is enabled by the key components of Industry 4.0: Cyber-Physical Systems, Internet of Things, Internet of Services, and Smart Factories. Driving the transformation are increasingly personalised customer needs and the growing trend of personalising products and services.
Industry 4.0, known as Industrial Revolution 4.0, began in 2013. However, the term “fourth revolution” was first used in 2011 at the Hannover Messe fair. In 2012, a group of specialists was formed in Germany to define the steps and principles for the future of factory automation. The result of the work was a report, presented in April 2013 at the Hannover Messe fairs. The report that initiated Industry 4.0 included information on
The experience of entrepreneurs in the development of Industry 4.0 results in the introduction and implementation of technological innovations in production and management to adapt to the growing demands of consumers. According to experts, smart factories are the most important element of the fourth industrial revolution next to the Internet of Things (allowing global access to data and machines). The idea of a smart factory is to get a product that meets individual expectations without large production costs.
A smart factory of the future is a place that is designed to match human expectations and needs. The modular smart factory concept uses the capabilities of the cloud that allow data to be managed anywhere and at any time. The data cloud allows factories to store and keep information, virtualise, as well as run analytics and calculation systems within the security of servers. A smart factory also includes advanced software for real-time data processing and analysis that enables effective presentation of results. New smart factory lines should be equipped with smart technology, i.e. sensors integrated with machines creating wireless data transfers. Cyber-physical systems are also an effective and functional solution for maintenance and mobile interfaces. Mechatronic and IT systems connect production lines, machines into global units. Autonomous systems, which are used to transport objects within a company, are a new solution to facilitate the production process. A smart factory also includes robots that create new robotic and autonomous production cells in collaboration with humans.
The essence of a smart factory as one of the most important elements of the fourth industrial revolution is the implementation of new technologies. They are designed to enable automation of manufacturing processes, improve efficiency, productivity, and reduce the cost of producing a product that meets growing customer expectations.
Base Group is committed to meeting the needs of our clients. To this end, as part of Industry 4.0, we periodically review new technologies that can be used in our processes. The quality and effectiveness improvement solutions introduced so far include:
WeldEye is a dedicated welding process control and management program. Base Group was the first Polish company to implement this system to ensure the optimum quality of machinery, equipment and welded metal structures produced.
Additive manufacturing enables rapid prototyping while expanding customisation options and reducing production costs.
Key Benefits of Additive Manufacturing:
3D scanning enables prototypes to be perfectly adapted to the actual requirements. The possible reduction in the number of prototyping iterations speeds up the production process.
Thermal imaging offers a major advantage in industrial process design, where precision and safety are crucial. Yet, thermal imaging cameras are not just for monitoring temperature. They are a revolutionary tool for identifying potential thermal hazards and optimising energy efficiency.
Key Benefits of Using Thermal Imaging at Base Group:
Automated Steel Product Grinding Station.
Dedicated to High-Mix Low-Volume (HMLV) production, this innovative solution redefines standards of precision and flexibility.
Featuring advanced vision systems, our proprietary automated workstation not only recognises different types of steel products but also automatically adjusts the processing method as required. We guarantee that each product is manufactured with precision, meeting the highest dimensional tolerances, thanks to customised parameters.
Benefits of our technology:
Assembly line with automatic feeding of assembled parts and automatic screwdrivers for bolts and nuts
Line concept — it all started with a unique and innovative line concept, meticulously planned with efficiency, process repeatability, reduced lead times and quality in mind,
Design and detailed drawings — our experts created a comprehensive design and detailed drawings, taking into account the latest Industry 4.0 trends.
Production — the project aimed to standardise working conditions to ensure the repeatability of products manufactured on the line. The line has been designed according to LEAN principles to ensure a smooth product flow. Bottlenecks have been eliminated thanks to a conveyor, which determines the production rate, and the duplication of stations with longer assembly times.
Assembly — Both the material and the process proceed in a single direction, maintaining the process flow. The production follows the ONE PIECE FLOW principle. At the line infeed, we deliver the individual product components; at the final station, we insert the finished, packaged product into the bulk packaging that is delivered to the customer.
Overseeing Cooperation — we ensured diligent oversight of the entire cooperation process, working with industry partners to achieve maximum synergy and efficiency.
Commissioning — the moment we had been waiting for — the successful launch of the WCO Line, confirming that our vision of Industry 4.0 has become a reality.
Project benefits — Increased production efficiency and standardisation. Thanks to One Piece Flow production, inter-operations transport has been eliminated, and the space used to store semi-finished products has been reallocated to the production of other products,
In a world of rapidly evolving technology, Base Group continues to shape the future with an emphasis on innovative solutions and the digital transition. Since its inception, our company has been committed to the continuous improvement of business processes through the use of modern IT tools.
Our Digital Transition Priorities:
Data: data is the heart of our transition. Skilful use of analytical tools leads to more efficient business processes and the unlocking of full human potential.
Innovation: we have focused on innovative solutions from the earliest days, which has allowed us to excel in a dynamic business environment.
Digital Transition Team: to ensure a concentrated effort, we have established a Digital Transition Team dedicated to the implementation of projects spanning our entire business.
Digitisation Map: together with our staff, we have developed a Digitisation Map, defining projects for the next 5 years that will accelerate our digital transition.
Mobile Warehouse Management project:
We have successfully implemented Mobile Warehouse Management, which has been fully integrated into the ERP system. This has allowed us to achieve full traceability of materials throughout the production process, significantly improving operational efficiency.
Digital Transition Goals at Base Group:
Digitisation: we aim to fully digitise the company, freeing up production capacity and increasing product quality.
Reducing Lead Times: through effective measures, we aim to reduce the time it takes to deliver the product to the customer.
For us, Industry 4.0 is not just a slogan — it is a real revolution of which we are a part. Through its digital transition, Base Group is heading towards a future where efficiency, innovation and quality are of paramount importance.
Base Group Ltd.
based in Koszwały, 29 Spacerowa St., Poland
entered by the District Court North Gdansk, VII Commercial Division of the National Court Register into the Register
of Entrepreneurs of the National Court Register with the number KRS 0000249201
VAT number: PL5832141328, Identification Number: 191298623, registered capital of 5 551 200 PLN
