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Embracing Industry 4.0 and digital transformation in manufacturing  

Industry 4.0 represents the digital transformation of manufacturing and production, integrating automation, artificial intelligence, and real-time data analytics with the aim of boosting productivity, enhancing flexibility and improving efficiency and ultimately give you a competitive advantage. 

The goal is to create smarter, more efficient, and better-connected systems that improve productivity and decision-making. 

Two key concepts that drive this transformation are: 

  • vertical integration – the internal connection of processes within a company, linking production, scheduling, and quality control to enable real-time monitoring, automation, and resource optimisation; and 
  • horizontal integration – the external coordination between suppliers, customers, and partners, ensuring seamless collaboration and data exchange across the supply chain. 

By adopting Industry 4.0 technologies, companies can boost productivity, enhance flexibility, and improve overall efficiency, staying competitive in a rapidly evolving market. 

Driving knowledge transfer in Industry 4.0  

Our Industry 4.0 cluster was established to promote digital technologies, facilitate knowledge sharing, and support businesses in their Industry 4.0 journey. One way we achieve this is by connecting members with technology providers, researchers, and industry experts so they’re able to explore innovative solutions for manufacturing challenges. 

One key service offered is the Industry 4.0 assessment through the Smart Industry Readiness Index (SIRI). This internationally acclaimed framework evaluates a company’s digital maturity, identifies priority investment areas, and provides actionable implementation strategies. 

Last week, we kicked off our program of knowledge sharing, with our first webinar for 2025 on digital forms and their role in Industry 4.0. This is one of the simplest yet most effective ways to digitise traditional processes into online platforms and digital workflows.  

Traditional paper-based workflows—such as hot work permits, safety checklists, and approval processes—often result in delays, lost paperwork, and inefficiencies.  

With digital forms, companies can: 

  • automate workflows – to reduce manual data entry and streamline approvals; 
  • increase accuracy – to minimise errors and ensure compliance; 
  • improve accessibility – to access forms in real-time from anywhere; and 
  • enhance safety & reporting – to capture and analyse safety data more effectively. 

This session was facilitated by SiteApp Pro - a New Zealand-based digital health and safety solution focused on simplifying compliance, improving safety workflows, and providing real-time insights. 

Key features of their app include: 

  • customisable digital forms for safety checks, incident reports, and audits; 
  • automated approval processes to ensure compliance and reduce delays; 
  • mobile accessibility for on-site workers to submit reports anytime, and from anywhere; 
  • integration with other systems to streamline data across job sites; and 
  • advanced reporting & analytics to identify trends and improve workplace safety. 

By leveraging digital tools like SiteApp Pro, businesses can enhance workplace safety, streamline operations, and reduce administrative overhead, aligning with Industry 4.0 principles. 

Inspired to take the next step? 

The shift to Industry 4.0 is transforming the manufacturing and fabrication industry where digital tools—such as online forms and safety management apps—play a crucial role in enhancing productivity, compliance, and efficiency.  

At HERA, we believe that businesses looking to future-proof their operations should explore how smart technologies and digital solutions can be integrated into their workflows. 

If you’re ready to start embracing technological solutions into your operations, consider an Industry 4.0 assessment or join our Industry 4.0 cluster so you can explore digital solutions like SiteApp Pro to optimise your operations. Contact our Senior Engineer – Advanced Manufacturing, Holger Heinzel to have a kōrero. 

You might also be interested in attending the Robotic Welding Workshop: The Essentials on 21 March 2025. You’ll gain a comprehensive understanding of robotic welding technology – the good, the bad, and the real-world impact on fabrication. Packed full of practical insights, you’ll get a hands-on-look at automation and become more confident in this space. We hope to see you there! 

Upcoming cluster meetings: 

📅 February 26 – Steel Fabrication Management: An Insider’s Guide to STRUMIS 
📅 March 13 – Giving Robots Sight: Advanced Sensors for Automated Welding 
🛠️ March 21 – HERA Robotic Welding Training Course (In-Person) 
📅 March 27 – Automation in Steel Fabrication: Opportunities & Challenges 
📅 April 08 – Optimizing Workshop Productivity: Strategies for Success 

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