Industrial IoT in Manufacturing
IoT has evolved as a force across industries including the manufacturing sector. IoT refers to a network of interconnected devices that communicate, exchange data, enabling smarter decision-making and enhanced operational efficiency. IoT integrates sensors, machines, systems and software to gather real-time data, automate process and optimize operations.
The manufacturing market has evolved with IoT driving profound transformation. From factory floors to supply chains, IoT enables smarter manufacturing solutions to enhance productivity, reduce downtime and improve product quality. With IoT, manufacturing companies are gaining insights into operations, are able to predict maintenance needs, track inventory and streamline production based on data-driven insights.
What is Industrial IoT (IIoT)?
Industrial IoT is a specialised branch of the broader IoT ecosystem. IIoT is specifically focused on manufacturing, energy, logistics and transportation among other enterprise departments. IIoT refers to the use of interconnected smart devices, sensors and software to collect, monitor and analyse data in real-time to optimize industrial operations and increase efficiency. Simply put, these are interconnected devices which communicate with each other, provide data to increase efficiency in manufacturing and distribution in large enterprises.
Traditionally, machines operated independently. By embedding IoT technology into equipment, manufacturers can get actionable insights to make data-driven decisions, for predictive maintenance and automation. IIoT also enables communication between multiple equipment to increase efficiency and understand areas for improvement.
Key Components of IIoT
IIoT is integrated into your existing machinery and involves installation of IoT devices and IoT sensors. IoT devices are physical devices with technology to collect and transmit data. These are integrated into industrial controllers, conveyor systems, CNC machines etc. IoT sensors are the eyes and ears of the IoT devices. They track and measure temperature, vibration, pressure, humidity, energy usage and machine performance. These sensors feed data to the cloud platforms or local networks for analysis.
Apart from IoT devices and IoT sensors, there are connectivity networks, data analysis platforms, edge computing devices and cloud infrastructures which perform their part to ensure a smooth performance of the system. Connectivity networks include communication protocols like WiFi, 5G, Ethernet etc. which help transmit data between devices. Data analytics platforms process this data in real-time and edge computing devices help analyse this data in real-time. The cloud platform stores data and manages them, making it accessible for deep data analytics and remote monitoring.
The Role of IoT Devices and Sensors in Manufacturing
IoT devices and sensors are the foundation of smart manufacturing. With real-time visibility of the entire production process, it is now possible to perform various actions, for example:
Predictive maintenance:
Vibration and temperature sensors provide information on equipment performance and can predict maintenance requirement helping avoid unplanned downtime
- Detect signs of wear and before failure occurs
- Schedule maintenance only when required
- Avoid costly breakdowns and unplanned downtime
Quality control:
Vision sensors and smart cameras can identify defective products improving quality assurance
Energy monitoring:
Sensors can track energy usage helping identify inefficiencies and reduce operational cost
- Identify power-hungry machines and inefficient process
- Automatic adjustment of HVAC, lighting and machine settings
- Track carbon emissions
Process automation & operational efficiency:
Data from multiple IoT devices together can be used to fine-tune production settings to improve output and reduce waste
- Track machine performance and production metrics live
- Identify and resolve process bottlenecks
- Automate repetitive tasks with IoT-powered robots
- Reduce human errors with digitised workflow
Smart Manufacturing: The Backbone of Modern Industry
Imagine a manufacturing unit where you push in raw materials and you get finished package on the other side. Well that may be an overkill but smart devices are capable of achieving nearly that. Smart manufacturing represents the next generation of industrial evolution. With cutting-edge technology to create automated data-driven production environment and IoT at its core, conventional factories can now be intelligent, responsive and connected to an ecosystem known as smart factories.
How IoT Contributes to the Smart Factory Concept
IoT is the core of the smart factory. With embedded sensors, devices and connectivity, an IoT allows manufacturers to monitor, control operations and optimize them in real-time. These smart devices continually emit data about temperature, pressure, machine status, product flows etc. of the production environment to enable manufacturers to automate processes with minimal human intervention. This also enables quick response to production issues, make decisions on process improvement, create adaptive systems that evolve over time among others.
IoT devices do not work alone. They are integrated deeply with other components of smart manufacturing including:
- ERP systems: Enables better business oversight
- MES: Track and document transformation from raw material to finished products
- Industrial automation systems: Automate process with PLC for process control
IoT devices bridge the gap between the physical and digital world. For example, when a sensor detects machine irregularities, MES can adjust workflow, notify maintenance team and update production schedule in the ERP system all automatically.
Smart factories are different from small operations. A small operation may control machines, conveyors, tools and operators but in a large operation, the system extends to managing lighting, HVAC, energy consumption, inventory management and supply chain, creating a complex yet efficient system which is adaptive and sustainable.