We are now witnessing the fourth industrial revolution, and IoT is going to be a crucial part in helping organizations join the Industry 4.0 wagon.
How SO?
The Internet of Things (IoT) has a huge potential to transform every aspect of an organization, starting with how it works, grows, and sustains itself to build a better outcome for itself in the future.
Early adopters of this technology like Nike, Tesla, Siemens, and Volkswagen have already started to show the results of the digital transformation catalyzed by IoT.
In this article, we will aim to find the impact of IoT in the manufacturing sector along with some of the benefits and challenges posed by this technology.
Use Cases of IoT in Manufacturing
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Remote Monitoring and Control
A production system in a factory or a floor bustling with the sound of keys tapping continuously can be easily managed via IoT systems. Focusing on the manufacturing industries, they have machines working round the clock.
IoT-enabled systems can help managers, supervisors, and workers monitor the machines and their conditions in real-time. The sensors installed in the factory can send distress signals about fire, gas leaks, and other incidents immediately so that the teams can take damage-control measures rapidly.
We can even have systems that can automatically implement damage-control systems. Supervisors can effectively monitor the worker’s activities, schedules, and production via automated reports generated from the system.
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Quality Control
Quality control is an essential but less spoken use case of IoT in manufacturing. Companies can set up automated robots and control systems to check and verify a product’s quality.
Once we feed the required information and analysis metrics to the system, it can check and verify the product’s quality according to the set parameters. Such elements like heat sensors can detect errors in products like motherboards easily. And for a human to verify the same can take up more time, effort, and money.
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Supply Chain Management
IoT can help create a hyper-connected supply chain management system and network, providing real-time insights into each segment. When all of your supply chain systems and operations are connected, the data generated from these peripherals can help maintain a smooth running system where the managers are always aware of the assets.
IoT in manufacturing within supply chain management can ensure real-time asset tracking, warehouse tasks automation, and better control of the inventory.
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Predictive and Proactive Maintenance
IoT can train the sensors and installed systems to learn and provide actionable intelligence for the machines working in the unit. The data generated is crucial for predictive maintenance, eliminating unplanned downtime, unscheduled machine repair, and maintenance.
These cost-saving benefits are provided by an IoT system that regularly monitors the machine’s health and performance only to share accurate insights. With a proactive system, we can also predict when a machine is bound to fail and make arrangements in advance to prevent unplanned shutdowns.
Adding IoT-based sensors to the workplace can transform any workplace into an advanced and hyper-connected unit. As IoT can make any workplace more efficient and proactive, it leads to building a productive workplace that has less issues and problems.
Also read : How to start Semiconductor Manufacturing?
Benefits of IoT in Manufacturing
By 2023, the total global spending on IoT is expected to cross $1100 billion. This means that almost every industry is gaining amazingly well from this technology, provided the implementation is correct. IoT has several advantages for the manufacturing industry as well. From better product quality to building a productive workforce, here are some benefits of IoT in manufacturing.
- Cost-Optimization: An IoT system cannot directly influence the price, but it provides the benefits indirectly. With IoT, manufacturers get production intelligence; they can track the materials, optimize the inventory, maintain machine health, etc.
With all these benefits, the production process improves in terms of speed, accuracy, and efficiency. When the production improves, it leads to better outcomes at lower costs.
- Better Products and Services: With IoT, one of the most important things you will get is information. Information on the products, raw materials, production processes, workers, and everything else. When you have access to all this information, you can preemptively work on improving the outcome by taking out the defective components in the production process.
This leads to manufacturing only the best quality products without having to face issues like defective raw materials, machines, and practices.
- Automation: Automation is one of the greatest benefits of IoT in manufacturing. Organizations creating an automated system with IoT at their disposal are benefiting from reduced downtimes, better decision-making, and predictive maintenance.
The inter-connectivity created by an IoT system ensures a seamless interaction between humans and machines. This also creates a harmonious workplace where there is only room for improvement.
- Completing KPIs: With an IoT system, the machines and sensors generate data regularly. This data is shared with computers that can create reports and visualizations from this data.
With this information, managers and supervisors can draw conclusions, modify the work processes, and change machines before they burn out and halt the entire manufacturing process.
While these are the major benefits of IoT manufacturing, their realization depends on practical implementation. It’s an infrastructure set up that requires expertise and personalization. Hence you must consult with experts to implement the same.
Challenges Faced by Manufacturers for IoT Implementation
Just like every other technology, IoT also has its own set of challenges and difficulties. For a manufacturer, understanding these challenges is essential.
- Large Investment: All the sensors, wiring, machinery, computers, etc., requires a substantial investment. Not to mention, manufacturers also have to bear the price of their maintenance and upgrades. While there is some heavy investment required, the return on investment won’t be quick.
- Security: Manufacturers do not have strong IT teams to take care of the systems and infrastructure. Cloud-based systems are prone to security risks, even though the providers of these solutions take the necessary measures to secure the networks.
Having said that, manufacturers need to have at least the minimum required team of IT professionals and specialists to maintain, secure, and implement IoT systems effectively.
- Integration of the Old and New: Not every manufacturer has the scale and capital of Nike. So, in the desire to create a better manufacturing system, a small-scale manufacturer may want to bring in IoT only to face integration issues with the old machines and new technologies.
Conclusion
The Internet of Things is meant to boost operational efficiency, reduce costs, and streamline the production process in manufacturing industries. While it presents several opportunities for manufacturing units to improve their bottom line, some challenges must be addressed. However, once you are all set IoT in manufacturing, you will experience a fantastic outcome driven by value addition on every level and an increase in customer satisfaction.
