IoT in Manufacturing – Use-Cases, Benefits and Challenges

Have you ever heard of the Internet of Things, also known as IoT? You can find many definitions of IoT, but let’s see what it really means. With IoT, people can connect to digital networks and the Internet using devices such as smartphones and computers to share information, interact, purchase products, and more. However, industrial IoTs use the same basic tenants and apply them to machinery to increase efficiency in the manufacturing process.

Before we go into more detail about application of Iot in manufacturing and its benefits, it may be helpful to first elaborate on the differences between IoT and IIoT.

• Internet of Things (IoT)- The Internet of Things is a network of everyday devices, devices and other things equipped with computer chips and sensors that can collect and transmit data through the Internet. Most of us use IoT every day.
• Industrial Internet of Things (IIoT)– Industrial IoT works in a network of sensors to collect critical production data and use cloud software to convert this data into valuable insights for product performance effectiveness.

The two definitions seem similar, but IIoT deals specifically with the world of construction.

How does IoT beneficial for the Industrial sector?

IIoT integrated tools deliver valuable real-time data, allowing manufacturers and machine operators to make informed decisions. There are many benefits of Iot in manufacturing and process looks something like this:

• The sensor collects data from the machine and sends it to the cloud
• Data is passed on to the quality monitoring system
• The analyzed data is sent to the end user

Industrial IoT in production

There are various factors driving the expansion of IIoT in the manufacturing industry. You can see that these factors work together, and that’s why manufacturers are now more inclined to work with IoT than ever before.

Reduce repair costs

With the industrial Internet of Things, companies increase resource usage, manage inventory better, reduce machine downtime, consume energy, and reduce overall operating costs create new sources of income. Smart Inventory Management Solutions can save up to 20% to 50% of an organization’s inventory carrying costs.

Less time for market

Faster and more efficient production and supply chain operations allow for more efficient production cycle time. Harley-Davidson, for example, took advantage of IIoT to rearrange its York, PA manufacturing facility and managed to reduce motorcycle production time from 21 days to 6 hours.

Automatic facility management

IIoT-connected sensors can monitor conditions like temperature, humidity, vibration etc. With automated facility management solutions, manufacturers can now classify and maintain conditions for equipment to work at ideal efficiency.

Improved safety

IIoT helps ensure a safe workplace. IIoT allows managers to monitor workers’ safety and limit hazardous activities with wearable gadgets. In addition to ensuring the safety of workers, IIoT addresses safety issues in potentially hazardous environments.

For example, in the oil and gas industry, IIoT is applied to monitor a gas leak as it passes through a pipe network and prevents potential injuries.

Cases of industrial IoT use in manufacturing:

The replacement of humans with connected devices in many manufacturing processes has completely changed the face of the manufacturing industry. Let’s take a look at the smart inventory management solutions.

Remote product control

IoT devices enable remote process monitoring and equipment configuration. First, employees can remotely collect information on production processes and check whether their results meet certain rules and requirements. Second, they can tune and configure equipment remotely, saving significant time and effort.

In addition, automated tools allow employees to correct any operational problems via virtual networks without being physically present, thus streamlining the operation and control of equipment. Virtual equipment monitoring allows employees to be aware of the device’s location, including movable property.

Estimated Maintenance

Human involvement is no longer need to identify potential abnormalities in equipment performance: IoT sensors embedded in machines can detect any operational fault (related to temperature, turn number, pressure, voltage, etc.), and the responsible personnel can give a warning about malfunctioning equipment, leaving employees only to take remedial action.

This practice, called predictive maintenance or predictable repair, allows technical service teams to detect and fix problems resulting from serious equipment failure, thus reducing downtime and costs.

Predictive maintenance also allows the integration of IoT-connected devices with advanced analytics software to estimate when technical support services are needed.

Industrial asset management

Using IIoT tools, manufacturers can receive and monitor real-time information on all their assets in a web or mobile application. Tracked assets can include:

• Vehicles delivering raw materials or manufactured goods (fleet management)
• Warehouse Items (Inventory Management)
• Resources during the manufacturing process

Thus, you can track and optimize assets at all production stages, from the supply chain to final product delivery. Proper asset monitoring enables quick and efficient identification of issues that adversely affect product quality or time-to-market.

Digital twin

Digital Twin technology is based on the Internet of Things, AI, ML and Cloud computing. It’s virtual replicas of physical objects, and their application on the construction floor can be very useful.

With virtual copies of equipment and spare parts, engineers and managers can simulate various processes, conduct experiments, detect problems and achieve desired results without endangering or damaging physical assets.

Challenges in the adoption of IIoT

With so many significant potential benefits, why are some manufacturers still lagging in adopting IIoT technology?

There are some significant challenges associated with adopting the Iot applications in manufacturing. Replacing large, mature systems has always required effort and energy, even in industry. The product is no exception.

Security

Security remains the most important concern for connect devices as data is transmitted between multiple nodes and can be extremely sensitive without proper security measures.

Today, manufacturing is the primary victim of hacking attacks. When traditional factories are convert to digital, they are turned into an IP-base system where every connected object becomes vulnerable to cybercrime. Therefore, manufacturers must prioritize safety and security by implementing efficient defence solutions.

To create a new connected environment, security strategies must be implemented. Older devices that incorporate IoT technology must be equip with protective equipment. Manufacturers must adapt to sophisticated hacking techniques to avoid data loss, intellectual property theft or other intrusions.

Skill Gap

With the increasing number of smart factories, the skill gap among employees is widening. Modern technologies applied in production require qualified experts and data scientists who can understand and operate new processes.

Lack of IoT knowledge and competencies can also make decision making difficult for industry executives. As a result, 2.4 million manufacturing jobs may fall over the next decade due to the skill gap.

To solve this problem, you should implement educational training on the Internet of Things and other technologies as soon as possible.

Seamless Integration

The second challenge is integrating all the devices into a larger product infrastructure and providing appropriate networking capabilities.

Companies should use intelligent solutions like artificial intelligence, machine learning, 5G connectivity, augmented reality or digital twins to solve this problem.

Final thoughts

IIoT can yield powerful performance benefits for any industry. However, integrating such tools properly requires effective technical instruction and coordination. As part of the futuristic workplaces, IIoT sensors and autonomous machines could bring valuable insights to businesses.

Still, it will take some time to overcome common challenges such as cybersecurity threats. And a reputed software development company can help you to achieve Industry 4.0 goals.