Hello! You are welcome to our blog post on IoT manufacturing.
In this modern age, the manufacturing industry, which is one of the world’s biggest, cannot do without digital technologies including the Internet of Things (IoT).
Natallia Sakovich from Sam Solutions posits that IoT is influencing “production enterprises, transforming business and operational processes”. The technology is also playing a leading role in “creating smart factories”. Taking this further, Nemi Nødskov, who is an expert IoT contributor, posits that the technology allows companies to leverage a network of sensors and cloud software, for collecting critical production data for valuable insights.
According to Nødskov, these insights drive high efficiencies in manufacturing operations. She further states that, adopting IoT manufacturing technology “enables manufacturers to improve productivity, enhance manufacturing and supply chain operations.”
In this blog post, we will dive into some important aspects of IoT manufacturing. We will offer you insightful perspectives that will help you understand the concept, and its benefits.
Want to learn more about IoT in manufacturing? Read on till the end.
Understanding the Concept of IoT Manufacturing
There are several reasons why many manufacturers are turning to IoT for sustainable solutions.
Traditional manufacturing systems face a lot of challenges. They struggle with how to achieve increased custom services, meet up with increasing customer expectations as well as dealing with the complex systems of supply chain. Even more troubling is this; they battle to overcome these challenges and stay on top of their manufacturing games.
The existence of these challenges and the dire need to overcome them for increased production and efficient operations are increasing on a daily basis. And as these needs keep increasing, digital technology solutions, including IoT are bracing up and expanding to accommodate solutions seekers with sustainable alternatives.
Understanding the Impacts of IoT in Manufacturing
IoT in manufacturing is driving a lot of changes and transforming production processes and systems. You can understand these impacts from three important angles;
- Operations
- Manufacturing and Supply Chain
- Outsourced Works
IoT Manufacturing Impact 1 – Operations and Real Time Data
IoT in manufacturing offer improved visibility services on important operations. And as this plays out, the digital technology is also enhancing the handling of resources by managements.
Traditional methods in the manufacturing industry use Manufacturing execution systems (MES) and Enterprise Resource Planning (ERP). Unfortunately, these technologies have some challenges which are not really favourable to businesses. This is especially true when it comes to using real time data for service optimisations.
For example, IoT offers detailed information on item location, arrange inventory and render available, the equipment status in real time. Such visibility and data quality offer manufacturers great opportunity to make the best decision. It also plays a leading role in production because there is now a reliable data who wants what.
Visibility and real time data by IoT offer manufacturers with viable monitoring and optimisations skills. These are in the areas of safety, production control in terms of quality and performance in the market.
The impact of IoT manufacturing with real time data is also very profound in the aspect of equipment performance and their uses. The digital technology offers real time data on the following;
- Equipment Working time
- Operation speed
- General outputs
All of these are possible with investment on IoT manufacturing monitoring tools. For example, real-time data from smart sensors, Supervisory Control and Data Acquisition Systems (SCADA), or with use of distributed control systems (DCS).
Several other ways that IoT for manufacturing offers visibility and real time data may include;
- Product quality control – For monitoring the movement of goods as well as the machines for productions.
- Product Quantity – For counting packaged goods right after automated production is completed
IoT manufacturing has an amazing way of boosting manufacturing processes. No wonder McKinsey says IoT technology pulls up greater performance beyond all the hypes it is getting.
IoT Manufacturing Impact 2: Manufacturing and Supply Chain
The role IoT in manufacturing industries extends to the supply chain management. The modern technology is viable for driving cost reduction and increased productivity.
Today, we can talk about smart supply chain process because of the impacts of IoT manufacturing technology.
IoT also injects real time data to the supply chain managerial functions for efficiency, With the technology, supply chain managers are always with accurate information on availability, location, status, and conditions of their items in real time.
Therefore, the impacts of IoT manufacturing help in the monitoring of finished goods. It ensures proper storage and offer enhanced route optimisation services to delivery agents.
This reduces number of wastes, especially with perishable goods. It is also reliable for preventing losses and theft within the supply chain.
When you combine all these impacts, the end results is timely delivery, increased profits and happy customers.
IoT Manufacturing Impact 3: Outsourcing
Many challenges exist in the manufacturing industry. These challenges are mostly related to the following; cost of operation, logistics, increase in demand, increase in customer expectations, complexities in the supply chain and local talents.
These are not challenges that every manufacturing company can handle. Most often, they lead them to tap into the benefits of outsourcing. But there is still an issue.
The outsourced works need to be transparent and follow global standards. In other words, they also need monitoring.
IoT manufacturing tools offer strong support for remote monitoring. So, the outsourcing manufacturing company can be monitored and their machines properly checked. IoT solutions also serves as a platform that facilitates teamwork and collaborative efforts of different manufacturing teams.
Wondering how IoT for manufacturing makes such remote monitoring happen? Well, through the use of Smart Connected Products (SCPs). These are IoT systems with smart sensors, hardware, embedded intelligence, connectivity and cloud software.
With SCPs, data handling is a seamless process. It works in real time and returns very accurate results.
Therefore, IoT manufacturing, through remote monitoring, enables managerial control of projects. Even if these projects are far away from the in-house teams.
IoT manufacturing enhances a lot of processes. It is digital solution that opens up more opportunities for business and help them in accessing those opportunities.
What are the IoT Benefits for Manufacturing
In IoT manufacturing offer some fantastic and enticing benefits in the manufacturing industry. Let us discuss a few of them.
Improved Efficiency and Productivity
Among several others, one of the key benefits of IoT in manufacturing is that it enhances operational efficiency. The digital technology offers this value in the manufacturing industry through the power of connectivity.
In IoT manufacturing processes, there are connections of different machines, equipment, and systems. These connections are leveraged by manufacturers for efficient monitoring in different critical areas; run time, predictive maintenance, and other things that will have negative imact in the workflow.
Manufacturers also utilise the technology for controlling of their manufacturing equipment and machines in real-time. This means they can shut down an equipment from remote locations to save energy and resources. They can also power their manufacturing industry using IoT technologies.
Overall, the use o IoT for manufacturing processes enables and enhances the following;
- Proactive maintenance
- Reducing downtime
- Saves energy
- Enhances effective management and operations
IoT Applications in Manufacturing For Vast Amount of Data And Analytics
The benefits of IoT implementation in manufacturing also enables the collection and processing of vast amount of data. This can automatically happen at different manufacturing stages for more data quality.
All the collected data are automatically analysed by analytical tools. In a few minutes, the result or reports of the analysis are ready with valuable insights for informed decision making.
The insights from a vast amount of data processing contain very useful information on manufacturing performance trends and areas of improvement. This leads to optimized resource allocation, improved product quality, and increased productivity.
Streamlined Supply Chain Management
Another benefit of IoT in manufacturing is its role in enhancing the supply chain. IoT wonderfully impacts the supply chain with smart sensors that monitor production processes and product packaging.
With this, the technology allows manufacturers to keep track of their movement throughout the supply chain.
Another aspect of the supply chain that IoT takes care of is the inventory management system.
With IoT tools, manufacturers can easily make important predictions, act on them and facilitates better inventory management.
IoT for inventory management is reliable for reducing losses, theft of goods and road accidents during delivery processes.
Powerful Automation And Connectivity
Furthermore, IoT in manufacturing allow manufacturers to leverage the powers of automation and connectivity across different processes.
The technology enables seamless communication between machines and IoT networks. While automation allows for the synchronization of operations without any human interventions.
Automation and connectivity functions of IoT solutions for manufacturing offers speeds in production processes. They also reduce the possibilities of human errors as a result of manual interventions.
So, these are the few benefits of IoT implementation from us. There are many others and you should consider doing more research on its benefits.
IoT Case Studies In Manufacturing Different Sectors:
Remote Control of Production Processes
Remote process monitoring and equipment configuration are possible with the use of IoT devices. The means that employees can remotely gather data on production procedures.
Then they can verify whether the processes themselves or the results they produce adhere to strict rules and specifications.
Second, they can remotely adjust and set up devices, which significantly reduces time, wastes and efforts. For example, during breaks or in no work days, managers or equipment operators can remotely shutdown any high energy consuming equipment not in use.
Additionally, IoT manufacturing allows automated devices to streamline the management and control of equipment. This enhances the staff to rquickly resolve many performance issues via virtual networks without being physically present.
Lastly, virtual equipment monitoring informs concerned staff of the location of devices, including mobile assets.
Quick notifications are also sent to management when an equipment is moved from position to the order. The allows manufacturing to take quick action towards safeguarding their resources.
Helps in Managing Industrial Assets
The digital technology enables manufacturers to quickly access and track real-time data on all of their assets. They can use the web or IoT mobile apps.
Examples of assets that can be tracked include; company cars, delivery vehicles, raw materials, manufacturing equipment, and other movable resources. Also, items in the warehouse can be tracked and managed.
Therefore, IoT applications in manufacturing helps manufacturers in effective management of processes at different stages of production. It is also a useful tool in the supply chain. This is why many instances of progress tracking are possible in the supply chain.
Let us also quickly add this; With IoT, it is also possible to quickly and effectively identify problems that negatively affect product quality or time-to-market.
IoT Manufacturing and Digital Twins
The Internet of Things(AI), Artificial Intelligence(AI), Machine LearningML, and Cloud Computing are all like the foundation for the digital twin technology.
The use of digital twins, which are virtual replicas of actual objects, is very beneficial to the manufacturing world.
For example, IoT allow engineers and managers to utilise virtual tools. They can simulate various processes, conduct experiments, identify problems, and get the results they need without endangering or harming physical assets
IoT Applications In Manufacturing for Maintenance Actions
In manufacturing companies, IoT sensors are embedded in machines to detect any operational issue (concerning temperature, turning number, pressure, voltage, etc.).
After identifying the issue, the sensors automatically notify responsible personnel about the deterioration of equipment. This puts the manufacturing company at a good advantage to take swift and proactive actions.
Using IoT technologies for maintenance processes frees up working space for staff because the technology eliminates human involvement in problem identification. This also eliminates human errors and inaccuracies at this level.
IoT manufacturing, predictive maintenance or predictive repairing techniques is a viable tool for the technical service teams. It is reliable for helping them to identify problems at an early stage before they lead to serious equipment failures.
This minimises the risk and possibilities of down times and more expenses on repairs.
IoT Challenges In Manufacturing Solutions:
IoT manufacturing technologies are not an all-perfect innovation. They have weaknesses, vulnerabilities and issues of security. We think its best if you were aware of some of those challenges for better decisions.
Let us dive into them right away.
Technologies and Data security concerns
While there are several other challenges, issues of data security stand out. This is a very serious concern because the more the connections the bigger it gets.
Risk of cyberthreats in IoT can lead to serious data breaches and authorised access if not properly managed.
One of the most effective means of managing such challenge is for manufacturers to put up strict security measures that will protect all sensitive data from unauthorized access.
Also, training of employees on data security is very important and upgrading of old technologies to modern ones are needed.
One thing with dealing with this challenge is that if there is a security vulnerability somewhere, malicious people can take advantages to cause serious harms.
Technologies Have Incompatibility issues with legacy systems
Incompatibility issues with legacy systems are common challenges in integrating modern technologies in industries.
As you may know, many of these manufacturing facilities rely on old and outdated technologies which may not be compatible with IoT devices, hence need upgrading.
There also situations that warrant a total revamp. Any of these leads to extra spending which may hinder the success.
IoT Manufacturing Technologies Have High implementation and maintenance costs
There is also the issue of high maintenance cost. Initial budget covering the sensors,
connectivity, and analytics platforms are already expensive.
But more issues may arise with continuous cost of maintenance. You will need to periodically perform system updates, software upgrades, and training requirements.
IoT Manufacturing Technologies Require skilled workforce for IoT integration
You will need your staff to be a bit tech savvy to embrace this innovative change and transformation. If they aren’t, that can be an issue because it may hinder the success of integration and the goals.
IoT Manufacturing Technologies: Our Conclusion
Implementing IoT for enhancing manufacturing processes is the way to go. It enables seamless processes and increases outcomes. It also allows you to tap into the powers of automation and remote monitoring for enhanced operations. Dealing with the challenges may cost you more money but we assure you that it is worth it.
