IoT-driven Digital Transformation in Manufacturing

There are numerous talks about digital transformation these days. The number of industries reinvented by modern technology continues to rise, as these industries manage to optimize obsolete workflows, improve overall productivity, or introduce completely new products to the market. That is also true for the manufacturing industry.

Many innovative technologies are entering the industrial sector today, but the Internet of Things is probably the biggest name.

IoT-based systems have already started to be used by major global enterprises for mission-critical tasks, whether Airbus is developing a “factory of the future” complete with wearables and sensors, or Komatsu is monitoring international mining activities.

How can IoT help various companies with their digital transformation programs? How can IoT in manufacturing help them? This article will guide you through the basics and answer your questions along the way if you are unfamiliar with the topic.

There are four major trends driven by the Internet of Things. The use of sensors in products and exploitation of the operational data they generate is disrupting not only the industrial manufacturing industry but also the ecosystem in which it operates, as:

To address challenges, such as those listed below, disrupting existing business models and moving to higher-value services have been necessary.

There is an Internet of Things that refers to a network that connects and communicates between appliances (or ‘things’). The Internet of Things also includes devices that were not designed to be connected from the beginning, such as refrigerators, harvesting tractors, or air conditioners.

Industry 4.0– the new era of industrial production favouring digital technology and encompassing automation – is enabled in part by the proliferation of IoT. Industry 4.0 challenges, like growing customer expectations and demands for customization, are addressed by IIoT, a subdivision of IoT that aims to streamline industrial workflows.

During IIoT implementations, manufacturers adopt specialized devices and software at every stage of the production process, from ordering raw materials to delivering finished goods to their clients. Managing each step of the process becomes more predictable and efficient.

Companies are required to be agile and responsive to changes in supply and demand in the era of Industry 4.0 if they want to stay competitive and achieve good profits. Enterprises are using IoT in manufacturing to perform these transformations on the shop floor and increase the ability to analyse data and make critical decisions.

Monitoring of operations in manufacturing facilities is enhanced by continuous logging of activities and machine status via sensors and devices installed throughout the facility. Monitoring can increase KPI adherence and lead to enhanced supply chain tracking as the next step.

A key feature of Industrial IoT systems is that they can gather and transmit data in real time, which means users can access real time information about industrial assets at any time, wherever they are located.

The need for instant sharing of data is crucial to making on-the-go decisions, receiving real time alerts, and responding quickly to problems. Staff can schedule maintenance based on needs rather than regular check-ups that may miss the problem, preventing downtime.

Custom Industrial IoT systems require multiple trials and performance checks before they can be considered suitable for large-scale enterprise implementation.

An idea for a new product begins with a rigorous analysis of its technical requirements, then a functional and schematic design and the prototype are developed. A proof-of-concept results after the design, routing, testing, and bringing up of a printed circuit board have been completed.

After the firmware design and development phase, the first device sample is produced and tested comprehensively. The team begins the production process and quality control of a pilot device, assuming the sample passes all tests and certifications.

Smart factories, also known as connected factories, use the Internet of Things to ensure that production processes are optimized versus specific processes. Using sensors, smart devices, and cloud-based data analytics systems, factories can increase efficiencies and streamline operations.

One instance of this is the smart factory operated by Stanley Black and Decker in Mexico, which increased the production of routers used in woodworking by 24 percent as a result of its IoT program. As an example of IoT deployment across numerous departments, the automotive company Magna Steyr tracked industrial equipment, such as tools and vehicle parts, implemented an automated order system, monitored components remotely via Bluetooth-enabled “smart packaging,” and used self-driving containers to transport parts.

In manufacturing, sensor-driven machinery monitoring is one of the most common uses of IoT. Workers can use it to determine precisely when and where maintenance is necessary. Using intelligent software, critical equipment can be monitored 24/7 for performance and malfunctions, and alerts can be issued automatically. This technology can be used not only to aid in the manufacturing process but also to protect manufacturers from warranty claims based on incorrect use of the product after shipment.

Industrial robot manufacturer ABB is using Internet of Things sensors to collect data about every robot’s performance, allowing engineers to anticipate equipment failure and prevent it from occurring. The FIELD System is a new robotics system developed by Fanuc and focuses on interconnecting machines, robots, PLCs, and sensors within a factory and enabling a factory wide Industrial IoT.

Manufacturing facilities with large asset portfolios have a higher risk of substantial losses from ineffective asset management. RFID transponders and Bluetooth trackers are commonly used in industrial IoT systems for inventory management, warehouse management, supply replenishment, and other processes.

Asset Intelligence from Caterpillar uses sensor data for advanced predictive analytics and provides fleet and vessel operators with advisory services. Engineers can now get access to detailed insights into the health of critical systems using AI-powered dashboards that combine siloed data. Not only do these insights prevent costly repairs, but they can also be used to boost energy efficiency.

All manufacturers are committed to protecting their workers. IIoT has made it easier for industries to keep employees safe and healthy in the age of Industry 4.0. Workers can now stay connected via wearable communication devices to a centralized safety system that monitors compliance with regulations and sends them safety notifications when potentially hazardous circumstances arise (e.g., where a worker enters a no-go zone).

Workers at North Star BlueScope Steel are equipped with wearable trackers that they attach to their helmets and wristbands. It combines health metrics sensors with environmental sensors that measure temperature, radiation levels, and toxic gas detection.

Despite the pandemic blow, the global Internet of Things spending is expected to return to double-digit growth in 2021 and achieve a CAGR of 11.3% through 2024. Industrial IoT opens up new possibilities for manufacturers in the form of applications and use cases never seen before. Several major trends that are driving innovation forward can be identified as technology continues to mature and expand.