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In the Industry 4.0 era, smarter machines are created by integrating existing technologies rather than continuously adding new functions. Design decisions such as implementing data analytics, cloud connectivity, AI-driven insights and IIoT communication enable greater intelligence while maintaining a simple and efficient machine architecture.

Integrating control, motion and robotics into a single machine requires more than high-performance hardware. Equally important is a common communication framework that enables different devices and systems to work together efficiently. Industry standards such as the OPC Foundation's OPC UA Robotics Companion Specification support interoperability between robots, motion systems and controllers, helping machine builders create more connected, scalable and flexible automation solutions while simplifying system integration and diagnostics.

Industry 4.0 not only revolutionises the way automation is carried out in factories but also introduced a major change in planning the life cycle of a factory long before it even comes to life. This is possible through the implementation of technologies such as digital twins to run simulations and tests in a digital environment. It reduces machine development time, decreases errors and additional costs related to correcting potential errors, and helps achieve more efficient commissioning.

When it comes to machine design, one of the key goals is the longevity and efficiency of the machine. New machine building solutions can help OEMs work towards this. Technologies such as IIoT and AI can support predictive maintenance, remote equipment monitoring, diagnostics, and data collection and analysis. By monitoring equipment and analysing its data, teams can identify signs of deterioration and potential issues earlier. This can help them plan maintenance before problems affect machine operation. Machine maintenance access should also be considered during design, so that equipment can be inspected and serviced.

Every change comes with its own consequences. To minimise risk, there are a few aspects that machine builders should assess before selecting automation components:

• system integration,
  
• cybersecurity
  
• scalability,
  
• talent shortfalls,
  
• support in managing change.
  

Together, these factors help OEMs assess whether the components fit the machine and what their implementation will require

Customers can influence product configuration before production begins. Smart manufacturing helps manufacturers connect demand with production: IIoT can help sense demand, reconfigure supply chains and adjust manufacturing processes. For OEM automation, a modular machine design can make it easier to offer defined configurations while keeping core functions consistent. In automation in machine design, machine builders should decide which modules or parameters can vary, how components communicate, and how each configuration will be tested and maintained. The available options depend on the product and the requirements of its customers.

For a broader overview of the principles behind machine building, see the four pillars of successful machine building.

Sources:

• Deloitte. (2025). 2025 Smart Manufacturing and Operations Survey: Navigating Challenges to Implementation, https://www.deloitte.com/us/en/insights/industry/manufacturing-industrial-products/2025-smart-manufacturing-survey.html.
  
• Industrial Internet Consortium. (2020). Digital Transformation in Industry, https://media.digitaltwinconsortium.org/wp-content/uploads/2024/10/Digital_Transformation_in_Industry_Whitepaper_2020-07-23.pdf.
  
• International Society of Automation. (2022, sierpień). Introduction: The Birth of Industry 4.0 and Smart Manufacturing, https://www.isa.org/intech-home/2022/august-2022/features/introduction-the-birth-of-industry-4-0-and-smart-m.
  
• OPC Foundation. (b.d.). Robotics, https://opcfoundation.org/markets-collaboration/robotics/.
  
• World Economic Forum. (b.d.). Smart manufacturing, factories and customization, https://www.weforum.org/stories/manufacturing-and-value-chains/smart-manufacturing-factories-customization.