The Internet of Things (IoT) is a wide area of connected technology that provides critical information in real time. In the manufacturing industry, data defines success. By monitoring conditions, cycles, and processes in real time, it’s possible to step in before a problem becomes costly or make adjustments to improve efficiencies.
IoT for manufacturing isn’t an option for many companies. Smart manufacturing, which typically includes numerous IoT sensors and devices, is leading the way in producing more, reducing costs, and minimizing costly liability claims. How does it work? Is it accessible to your mid-sized manufacturing company?
What Is IoT and Why Is It Transforming the Manufacturing Industry?
IoT, or more accurately for our use here Industrial Internet of Things (IIoT), refers to the use of sensors, PLCs, HMI’s EMS, visual inspection devices, etc., placed at various locations to transmit data from the manufacturing floor to a computer system. The sensors connect numerous systems and devices across your location through the internet.
It doesn’t just link them but allows for communication. Data can trigger actions or responses, both by people and machines. Sensors can prompt changes in operation, optimization processors, or inform about equipment concerns. IIoT’s embedded sensors and connected devices capture and analyze data to provide operational processes through networked industrial control systems.
IoT in manufacturing specifically covers the use of:
IIot devices
IIoT sensors
Connectivity into the industrial process
Data streams in, your operational technology analyzes it, and changes happen that enable smarter and more insightful (and often optimized) workflows. It’s like having analysts on the floor constantly, and capable of making executive decisions effectively.
Core Benefits of Implementing IoT in Manufacturing
With the support of a manufacturing software company, it’s possible to create a streamlined, highly specific strategy tailored to your operations. However, in every situation, there are several core benefits that come from implementing IoT in manufacturing:
Process optimization
Ultimately, IIoT improves operational processes. The traditional process worked, especially for companies utilizing strategies such as Six Sigma or lean. However, humans create errors, and limitations exist because of the manual requirements of these tasks.
IIoT changes the game by embedding sensors that provide real-time machine data as well as analysis of that information. This enables actionable insights that teams can take immediately. The result? Fewer bottlenecks and better access to less obvious manufacturing trends that could influence product outcomes.
Improved inventory management
Inventory is certainly not something that manufacturing companies can overlook when it comes to maintaining positive cash flow. However, legacy products lag behind real-time data. The use of traditional supply chain management tools requires time, whereas the use of IIoT creates real-time transactional data.
This means IIoT can optimize WIP management. It can provide insight into the utilization of waste and scrap. It also enables planning for upcoming projects in a more efficient manner, cutting out the extra steps involved in traditional methods. With advanced inventory tracking in transactions, such as with the use of RFID tagging and linked scanning technology, your inventory is accurately managed, start to finish, and adjusted as and when needed.
Predictive maintenance improvements
Manufacturing comes to a grinding halt when systems must come down due to wear and tear or equipment breakdowns. Yet, it’s very common for companies to find themselves unable to stop production to tackle predictive maintenance that seems like it could be “put off” for a few more weeks.
With IoT strategies, predictive maintenance happens when data from embedded sensors communicates the need for it. Precise machine utilization like this enhances operational efficiency and minimizes breakdowns and quality assurance problems. It improves your manufacturing process by keeping it up and operational longer, while still ensuring that maintenance is done when needed.
The Strategies for Using IoT in Manufacturing
How can you apply this technology to the way your business is operating now? Look at these trends in IoT for manufacturing and the impact it is making.
Data collection
Smart manufacturing, incorporating IoT, enables real-time collection of data throughout production. AI and ML-powered analytics tools then utilize that information to make decisions to improve operations or to offer suggestions for changes. This impacts quality control, inventory tracking, and machine performance.
Disparate device connectivity
IoT in smart manufacturing places sensors and devices in machines and systems to enable constant communication. Management teams can consistently monitor every aspect of the production process. This creates a dynamic ecosystem to improve efficiency and precision.
Enhanced supply chain visibility
Connectivity extends, potentially, beyond the manufacturing location. It enables the tracking and monitoring of all assets, including raw materials and final goods. This tracks the entire manufacturing process, ensuring temperature- and condition-specific requirements are met at all stages. It also creates immediate insight into delays, enabling a company to react immediately as needed to keep projects on time.
Improved safety
IoT in manufacturing may also reduce the risk of worker safety risks and compliance violations. With connected devices and sensors, management teams can consistently monitor for high-risk conditions, such as machine failures or temperature changes. This enables faster response times to conditions that warrant immediate support.
Remote control and monitoring
As noted, IoT facilitates remote monitoring, but some systems go a step further to incorporate control as well. With remote monitoring, companies can make decisions, update processes, or alter machine function without leaving the office. This can be done at every stage of the industrial process, ensuring improved efficiency in operations and potentially reducing labor costs.
Energy management
IoT-enabled energy management enables manufacturers to minimize energy-related costs and overruns. Properly placed sensors can detect energy waste and recovery opportunities, allowing for immediate changes that reduce operational costs. Automated monitoring systems allow a constant stream of information to create energy audits. There is no delay in making those changes, and no human interaction is necessary.
Digital twin technology
A digital twin in manufacturing is the creation of a virtual representation of a work process and factory function. Using sensors placed in strategic locations, management can create a virtual twin of the factory floor with very accurate details. Then, this digital twin allows management to test out various configurations and changes without impacting current production. This can lead to cost reduction and increases in productivity, while also creating significant improvement in quality.
The application of IoT in smart manufacturing is a way to streamline the production process, have far more control over it, and minimize costs along the way. Utilization of the most modern strategies allows any-sized organization to make better decisions in optimizing its operations. And that, over time, can lead to profitable outcomes and a strong competitive advantage.
Article Contributed by John Maher is VP of Product Strategy, Synchrono.