Article | January 8, 2021
The pandemic is considered a catalyst of change. It has forced many industries worldwide to transform and adapt to various digital solutions. A collection of advanced technologies such as IoT, artificial intelligence, machine learning and more have been widely adopted to support innovation-driven growth strategies. Majority of industry leaders are describing these technologies as industry 4.0 revolution. Entrepreneurs from the manufacturing industry are among them.
Many novel opportunities in the manufacturing industry are flourishing with the addition of IoT. The idea of digital transformation has become a necessity rather than an add-on cost for companies. Having said that, the manufacturing industry is on the cusp of a revolution—the internet of things revolution! According to IDC, in 2020, the manufacturing industry experienced notable growth, with a CAGR of 12.4%, which forecasts by 2025.
The internet of things in manufacturing enabled smart manufacturing, known as Industrial IoT (IIoT). This development introduced transparency of processes, products, assets, resources, connectivity, advanced analytics, automation, and other advanced-manufacturing technologies. The addition, the internet of things in manufacturing gained momentum as it helped companies transform their operations. It benefitted businesses in various aspects such as production efficiency to product customization, improvements in speed to market, service effectiveness, and even in new business model creation.
A recent MPI 2020 Industry 4.0 study revealed that 83% of manufacturing leaders consider “industry 4.0 is extremely important” to their companies, and 56% believe that “Industry 4.0 will have a significant impact” in the next five years.
This blog will give you an overview of IoT as well as how its impact is influencing and transforming the manufacturing industry.
An Overview: The Internet of Things
IoT refers to a network of everyday devices, machines, and other objects equipped with computer chips and sensors. It helps in collecting and transmitting data through the internet. There are several applications of IoT in manufacturing like creating digital solutions, security systems, and communication medium or for upgrading manufacturing processes. These implementations are affecting the overall ecosystem of businesses.
IoT is not a novel technological concept but it is being widely circulated in the manufacturing industry in the current times. It is now a developing trend and an innovative technology, enabling rapid data flow while providing the ability to monitor and manage processes in real time.
What is IoT in manufacturing? IoT in manufacturing refers to the Industrial Internet of Things (IIoT). It includes interconnected sensors, instruments, and devices networked together with computers’ industrial applications, including manufacturing and energy management. Industrial IoT in manufacturing shapes organizations with greater capabilities and connectivity to increase their pace of identifying bottlenecks in processes and manage operations with greater agility.
It has been observed that during the pandemic, the IoT in manufacturing has gained prominence because now the goal is to create a completely automated process and turn it into a smart factory for the years to come.
Top Use Cases of Internet of Things in Manufacturing
Without visibility, there is no accountability. The value of the IoT in manufacturing is rising unprecedentedly after the manufacturing industry faced challenges during the pandemic.The novel applications of IoT in the manufacturing industry offer hope for massive opportunities to enter in the future. The industrial IoT in manufacturing is slowly transferring traditional manufacturing supply chains into dynamic, interconnected systems, helping to change the way products were being made before and ensuring better safety for human operators to a high level.
So, how is IoT used in manufacturing? Here are the top three use cases of IoT trends in manufacturing:
•Remote monitoring and operations
•Predictive maintenance and smart asset management
•Autonomous manufacturing
Other than this, the need of IoT in manufacturing is also processed by wireless connectivity. Today, IoT depends on low power and long-range, as the Narrowband (NB) standard addresses it. Thus, there are now a host of IoT use cases, including smart metering, asset tracking, logistics tracking, machine monitoring, and more.
However, as the comprehensive 5G connectivity is about to enter the technology sphere, there will be a new level of speed, efficiency, and performance, which will help unlock new IoT use cases in the future. A 2020 report from Bloor Research reveals that the future of 5G, edge computing, and IoT are critical enablers for the manufacturing industry.
The Role of the Internet of Things in Manufacturing
The applications of IoT in the manufacturing industry have been there for a long time. However, the pandemic forced many manufacturing units and factories to adopt the emerging IoT trends in manufacturing to revolutionize the mass production of goods and boost other industries' output. The benefits of the IoT in manufacturing are becoming popular by the day. Whether it’s about gathering data from multiple machines or delivering real-time data to the manager of operations, the results of this are enhanced operational performance and reduced workload.
Apart from this, goods are tracked and equipment maintenance is predicted easily. All of these functions, through analysis, help manufacturers to identify factors of failure or malfunction. By knowing about it on time, they can take appropriate actions and measures to overcome them. So, whether it is IoT in car manufacturing, IoT in apparel manufacturing, IoT in automotive manufacturing, or other industries, IoT is booming in every way. Even the companies specialized in making manufacturing machines are following the latest IoT trends in the manufacturing industry.
To get more specific about the impact of IoT in the manufacturing industry, here are the most sought-after roles:
Quality Level 4.0
Most manufacturers faced difficulties while maintaining quality consistency, as the pandemic forced them to reduce human interaction at work. This aroused complexities in various manufacturing processes. So, by implementing IoT, companies have easily been able to produce good quality products through multiple applications, latest machines, equipment, and tools. In this way, the IIoT’s impact in the manufacturing industry will indeed enhance the quality level of products to manufacture in the future.
In addition, as IoT has a mass of applications in manufacturing, it is also facilitating the production rate of products. This is one of the major benefits of IoT. It increases production rate by automatically monitoring the development cycles at each stage. In this way, the quality aspect of a product remains under observation throughout the production process.
IoT Enables Power of Prediction
Predictive maintenance is a big thing. One of the significant answers to how IoT is being used in manufacturing is that it improves operating efficiencies. It also ensures that factory equipment and other assets are adequately working, which stays a major priority for manufacturers. Even a small malfunction can lead to substantial delays in production, which could delay or even cancel orders. In these situations, IoT technology helps to overcome these challenges. The deployment of wireless sensors throughout the machines can easily help managers detect issues beforehand and resolve them. This shows the power of prediction it provides.
The emerging IoT systems supported by wireless technologies have sense-warning signs in equipment that sends data to the maintenance staff so they could proactively repair the equipment. This avoids major delays in future production schedules. In addition, manufacturers could also gain other benefits of IoT by getting safer plant environments and increased equipment life. This is how the Internet of Things is becoming crucial for the manufacturing industry, especially after the pandemic, and is creating possibilities for manufacturing companies to gain predictable revenue in future.
Supply Chain Management
Emerging applications of IoT in the manufacturing industry are allowing companies to monitor all the events related to supply chain management. It includes shipments of supplies, tracking of transportation services like shipping containers, logistics data, and more. Data analyzed through devices could also help companies improve logistics by finding problem areas and resolving them in no time. Apart from this, IoT devices also eliminate a big chunk of manual documentation related to operations and others with a novel Enterprise Resource Program (ERP). This new invention of the Internet of Things in manufacturing facilitates cross-channel visibility into managerial, financial, and operation departments.
Remote Production Control
Many manufacturing companies relocated their computational resources to a custom cloud or connected on modern BAAS (backend as a service) or PAAS (platform as a service) platforms. Thanks to the IoT applications that benefitted the manufacturing industry during challenging times in the pandemic. In this case, the data is transmitted to the industrial automation system. In addition, it controls the overall process of machinery as well as production. IoT in steel manufacturing, oil and gas industries, and power generation have already gained benefits from this function of IoT technology. These industries used IoT devices and created a control system distantly. Harley Davidson, Cisco, and GE are some of the finest examples of using IoT in manufacturing. They have set history by reaping the best benefits of the Internet of Things in manufacturing and overcame hurdles bravely during the pandemic. Their IoT-driven manufacturing process achieved a massive production rate in comparison to other industries during the pandemic phase.
Cisco developed a “virtual” manufacturing execution system platform (VMES) through leveraging technologies such as the cloud, big data analytics, and the internet of things to gather real-time information from production machines. In the same vein, Harley Davidson and GE connected every asset on the plant floor and production to IoT devices and tracked performance in real-time. They installed 10,000+ sensors that looked after machine operating data, measured temperature, humidity, and air pressure in real-time without any human interaction.
So, information obtained through distant control systems provides a much clearer and faster insight into the actual production in the field. It assists staff in analyzing all the data and makes all the operational tasks convenient. This makes the IoT technology a core instrument in ensuring safe automated production, monitoring the workers, and helping staff members to maintain a proper workflow of business.
With all that said about IoT’s role in the manufacturing industry, does this mean that the industry is on the edge of leading with IoT? The answer is ‘yes.’ This is proved through some findings that are as follows:
• 76% of manufacturers plan to increase their use of smart devices in manufacturing processes in the next two years.
• 63% of companies have already implemented IoT technologies into their products, especially after the pandemic, and ready to supply manufacturers globally.
• 71% of them believe that IoT will have a significant impact (24%) or impact (47%) on their business over the next five years.
The Right Time to Invest
Manufacturers globally believe in the power of IoT and have developed the confidence of implementing it now. The idea of smart manufacturing with IoT is to use connectivity technologies such as industrial networks, Wi-Fi, M2M, and more to link factory automation assets, such as production equipment, robots, and more. This also extends to take advantage of end-user apps, such as MES, PLM, ERP, and mobile devices for more active and precise business decision-making.
Hence, getting an IoT solution for your manufacturing business is essential, mainly as the pandemic has shifted the paradigm of business operations. To gain IoT’s competitive advantages, considerable investments are necessary for your business to provide your staff with proper working methods. For manufacturers, globally, the IoT’s impact will be seen in every aspect of their business and thus allow them to thrive even in the most difficult of times in the future.
Frequently Asked Questions
How to implement IoT in manufacturing?
There are many factors to be taken into consideration for implementing IoT in manufacturing. However, some of the best are discussed below:
• Businesses should invest more at an early stage of planning to understand the needs of their end-users
• Introduce digitally forward tools
• Identify risk areas of manufacturing
• Introduce a broad range of technologies including cellular, Wi-Fi, Lora, and Sigfox as advanced communication system
What is IoT in manufacturing?
Industrial IoT (IIoT) in manufacturing adds intelligence to manufacturing equipment, processes, and management. It enables smart manufacturing solutions with the help of connected sensors and devices at the network edge.
What are the six levels of IoT?
The six levels of IoT are as follows:
• Device
• Resource
• Database
• Analysis
• Application
• Controller service
What are the types of IoT?
The leading types of IoT are:
• Low Power Wide Area Networks (LPWANs)
• Cellular
• Wi-Fi
• Bluetooth
• Radio Frequency Identification (RFID)
• Zigbee.
What are the components of IoT?
The various components of IoT are:
• Sensors/Devices
• Connectivity
• Data
• Analytics
• Cloud/server infrastructure
• Applications
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Article | April 13, 2020
Two recent projects demonstrate the potential of digital manufacturing in translating life-saving ideas to real-world products, both at scale and in enough time to make a difference. The first is a ventilator designed by a team of researchers at the University of Minnesota to be easy to use, and, of more immediate concern, easy to manufacture quickly. The second is a facemask from Zverse, a 20-employee design firm. Both relied on the same manufacturing partner to bring their ideas to fruition: Protolabs, a Minneapolis-area provider of CNC machining, injection molding and 3D printing services where automation extends beyond the shop floor.
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Manufacturing Technology
Article | December 10, 2021
IoT in the manufacturing industry introduces a superior technology that is coming up as a blessing for the industry. Manufacturers are enjoying one-of-a-kind benefits and returns on their reinvestments in IoT. Benefits such as enhanced productivity, work safety, reduced downtime, cost-effective operations, and more such benefits of IoT in manufacturing make it more and more popular with each passing day.
The global IoT market is estimated to reach a value of USD 1,386.06 billion by 2026 from USD 761.4 billion in 2020 at a CAGR of 10.53 percent over the forecast period of 2021-2026. So the whole worldwide market of IoT has a bright future in the following years.
“As technology takes over and enhances many of the processes we used to handle with manual labor, we are freed up to use our minds creatively, which leads to bigger and better leaps in innovation and productivity.”
– Matt Mong, VP Market Innovation and Project Business Evangelist at Adeaca
Let’s check out below some exciting facts about IoT in manufacturing and see how IoT makes a difference in the manufacturing industry.
IoT in Manufacturing: Some Interesting Facts
According to PwC, 91% of industrial/manufacturing enterprises in Germany invest in "digital factories" that use IoT solutions.
According to the International Federation of Robotics (IFR), China employs more industrial robots than any other country (many of which are connected to the internet in some way).
According to IoT Analytics, the industrial sector spent more than $64 billion on IoT in 2018 and expects investment in Industry 4.0 to reach $310 billion by 2023.
According to the Eclipse Foundation, most IoT developers are focused on developing smart agriculture systems (26%), while industrial automation is another big focus area (26%). However, home automation is dwindling in popularity, accounting for just 19% of projects.
How Does IoT Work for the Manufacturing Industry?
The Internet of Things (IoT) is a network of interconnected devices that communicate with one another and with other networks. While IoT-enabled devices are capable of various tasks, they are primarily employed to collect data and carry out specific tasks. The implementation of the Internet of Things in manufacturing is often referred to as the IIoT, or Industrial Internet of Things.
IoT makes use of 'smart' devices to collect, process, and act on data. These intelligent devices are equipped with sensors and other software that enable them to communicate and exchange data inside the network.
IoT-enabled equipment gives crucial real-time data that enables manufacturers or machine operators to make informed decisions. So, how does it function in practice?
Sensors capture data from the system and transfer it to the cloud, where it can be analyzed.
The data is transferred to the quality assurance system.
The data that has been analyzed is forwarded to the end-user.
How the IoT is Improving Manufacturing Business Operations
The Internet of Things (IoT) has numerous benefits for the manufacturing industry. We'll go over some of the significant benefits that the Internet of Things brings to the manufacturing business.
Energy Efficiency Solutions
Energy is a high cost in manufacturing. Unfortunately, the current industrial energy infrastructure can only track excessive energy consumption.
The utility bills include the factory's energy consumption records. But, unfortunately, nobody can break down energy consumption to the device level and find out the underperforming pieces. Some energy usage monitoring tools exist, but they only provide partial data, making system analysis difficult.
IoT can help by giving device-level energy data. The sensors will detect any underperforming devices in the network and alert you so you can take action. As a result, the technology can help you reduce energy waste and find other ways to save it.
Market Forecasting
Data is required to determine trends and quality of production at a manufacturing facility. It also helps manufacturers plan and anticipates changes. These forecasts can help with inventory management, employment, cost control, and other operational procedures. Thus, IoT technology makes it easier to foresee and optimize customer requirements.
Proactive Maintenance
The Internet of Things (IoT) uses sensors to gather data about assets' health and productivity. In addition, it uses advanced analytics to give actionable information. These are presented on an appealing dashboard connected to your smart device. This allows for predictive maintenance to be used in the manufacturing industry.
Superior Product Quality
Every manufacturer is determined to produce a high-quality product at a low cost. Therefore, a minor quality modification can have a significant influence on the manufacturing firm.
Customer happiness, waste reduction, sales, and profit can all benefit from high-quality products. But making high-quality products isn't easy.
The Internet of Things (IoT) can assist you in this endeavor. Poorly set, calibrated, and maintained equipment are some of the main reasons for low-quality products. Worst of all, many small things sometimes go ignored as the final product seems perfect. Quality tests show the product is fine, but your consumers start having problems after a couple of months.
Imagine the resources needed to identify and correct the problem. Sensors in an IoT network detect even minimal tweaks in setup and alert operators. The team might momentarily stop production to address the issue before the production cycle gets complete.
Rapid and Informed Decision-Making
The IoT can dramatically improve organizational decision-making. It unlocks vital data about network equipment performance and delivers it to the right person.
Managers and field operators can use this data to improve plant processes and overall production.
In addition to these significant benefits, IoT in manufacturing can help manufacturers improve their manufacturing operations and construct a unit that meets the vision of the smart factory of 2040. The future beyond IoT would be the icing on the cake for all of us, as technology has always amazed us.
Imagine the day when IoT and AI merge, and the virtual gadgets controlled by IoT are the next major milestone. Then, the ideal combination of robotics, AI, and VR may reduce the manufacturing plant size and cost while increasing the output to a level that is unimaginable and unattainable as of now.
Airbus Improved Production Efficiency with Its Factory of the Future Concept
It's a massive task for a commercial airliner to be assembled. The expense of making a mistake throughout making such a craft can be significant, as there are millions of parts and thousands of assembly phases. Airbus has established a digital manufacturing effort called Factory of the Future to optimize operations and increase production capacity. The company has installed sensors on factory floor tools and machinery and supplied workers with wearable technologies, such as industrial smart glasses, to reduce errors and improve workplace safety. The wearable allowed for a 500% increase in efficiency while eliminating nearly all mistakes in one process named cabin seat marking.
Final Words
While the benefits of IoT devices have long been a topic of discussion among technology enthusiasts, the incorporation of IoT in manufacturing is creating a new buzz in the industry. The benefits of IoT in manufacturing, such as remote analysis of operations, processes, and products, are assisting manufacturers in establishing a more productive manufacturing unit. As a result of these benefits, IoT use in manufacturing is accelerating. Recognize the IoT's potential and take a step toward incorporating it into your manufacturing operation in 2022.
FAQ
What is the Industrial Internet of Things (IIoT)?
IIoT stands for Industrial Internet of Things. It uses data to improve industrial efficiency. To enhance industrial performance, it uses embedded sensors, cloud data, and connected devices.
Why is the IoT changing manufacturing?
Real-time monitoring of machines and accurate reporting for better decisions are possible through IoT. This improves business strategies and project control. Thus, the Internet of Things has a significant impact on the profitability of any manufacturing company.
How does the IoT transform the way we do business?
We can use data collected by IoT devices to improve efficiency and help organizations make better decisions. They tell organizations the truth, not what they hope or believe.
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Industrial 4.0
Article | March 29, 2022
Smart manufacturing industry 4.0 is based on the concept that machines should be able to communicate and collaborate to produce new products and services. Industry 4.0 solutions, often known as the fourth industrial revolution, are transforming the way we live and work—and significantly impact the global economy.
“As companies learn to tap into the potential of the vast amounts of data emerging across all areas of operations, decision-making and action-taking are taken to a new level.”
- Thomas Erwin Global Head of KPMG Lighthouse, CoE for data-driven technologies
Industry 4.0 solutions or technologies are used to alter the way industrial companies function. Industrial IoT, automation and robots, predictive maintenance, simulation, additive manufacturing, and IoT analytics are a few of these technologies.
In this article, we will take a look at how these industry 4.0 technologies are accelerating the shop floor activities to optimize the overall manufacturing operations.
Industry 4.0 Technologies and How They Can Help
Robotics: The application of computer-controlled robots to manual tasks, such as assembling.
3D Printing: Manufacturing a three-dimensional item by layering material under computer control.
Sensor Technology: A sensor capable of detecting and responding to environmental circumstances.
AI and Machine Learning: Enables the extraction of fresh insights and decision-making capabilities from massive amounts of information.
Digital Twin: Creates digital replicas of operations to diagnose problems and test operational adjustments.
Augmented Reality: This allows for new data visualizations to increase worker productivity.
Communications Network Infrastructure: Enables data transit between machines and humans and comprehensive system integration.
Big Data Platforms: Stores, manipulates, and shows data while also providing new degrees of operational management.
Digital Supply Chain: Provides real-time visibility into supply and demand to eliminate network delay.
IoT Enabled Cybersecurity: New cyber security techniques are required due to newly digitized and automated activities.
Improve Shop Floor Operations with Industry 4.0 In Manufacturing
Digitize Each Process
Recognizing machine availability, idle state, running status, efficiency, and product quality data in real-time is crucial for any shop floor supervisor or manager to meet the actual vs. target production for that day.
Digitizing the manufacturing operations enables everyone on the shop floor to precisely comprehend machine parameters and meet day-to-day production targets.
With real-time data collection, supervisors, operators, and plant managers can easily track the overall effectiveness of their equipment.
Track OEE Using IoT and Mobile App
Capture and monitor the accuracy of sensitive data in real-time using IoT devices to record and deliver threshold alerts to supervisors’ and plant managers. This can be done using the mobile app to examine each machine's performance and efficiency. The data acquired by the OEE monitoring software will aid the organization in increasing its overall productivity rate.
Keep Track of Product Counts
Monitoring production in real-time is difficult for most operators, but digitizing the process with a TV dashboard enables operators to keep track of the number of goods produced on the machine. A production monitoring system allows operators to keep track of the number of products manufactured each day compared to the expected number.
Assign Tasks Dynamically
Supervisors spend considerable time allocating jobs to operators and tracking their efficiency. Digitizing job card processes makes it easy for supervisors to assign tasks seamlessly to operators on a shift or transfer tasks to others in the absence of an operator via automation. It also efficiently tracks each operator's performance across multiple changes.
Keep Track of Machine Failures
Maintaining accurate machine uptime and downtime records is a constant challenge for operators. With the arrival of industry 4.0 technologies such as industrial IoT solutions in the market, operators now have real-time data on machine uptime and downtime, allowing for smooth analysis of machine performance. In addition, preventive maintenance software helps operators and managers monitor equipment data while on the go. Unplanned downtime and frequent repairs are incredibly costly, and prevention is critical to achieving a higher return on investment.
Utilize Data with a Predictive Maintenance System
Tracking machine data and identifying machine downtime in real-time can significantly lower the TCO (Total Cost of Ownership). Collecting machine data for at least five years and evaluating it using a predictive maintenance system powered by AI and machine learning will help your organization reduce unplanned downtime or unexpected machine failures and increase production.
In the future, with predictive maintenance software, industrial businesses can figure out what will happen to their machinery and how to avoid it.
Many manufacturing organizations have already begun to utilize the potential of industry 4.0 solutions to improve their day-to-day operations and efficiency to satisfy the ever-changing and expanding needs of their customers, resulting in an increased return on investment.
Final Word
Industry 4.0 technologies enable firms to optimize their daily manufacturing operations and business processes in various ways. As a result, industry 4.0 solutions are generating significant interest in the industry, and several businesses are implementing them on their shop floors. Apple, Amazon, General Electrics, Siemens, Ford, and Bosch are some of the industry's biggest employers of industry 4.0 solutions.
However, manufacturers must implement these industry 4.0 technologies correctly. Instead of going with the flow, examine your business requirements and choose the appropriate technological implementation.
FAQ
Why is Industry 4.0 so critical?
Industry 4.0 technology helps you control and optimize your manufacturing and supply chain processes. It provides real-time data and insights to help you make better business decisions, increasing your company's productivity and profitability.
What is Industry 4.0's key objective?
Industry 4.0's primary purpose is to propel manufacturing forward: make it faster, more efficient, and customer-centric. Also, push beyond automation and optimization in search of new business prospects and models.
What are the benefits of smart manufacturing?
Improved efficiency, leaner processes, maximum flexibility, enhanced agility, innovation, and higher-quality products are some of the significant benefits of smart manufacturing.
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