IoT in Manufacturing 8 Trending And Use Cases In 2023
The Internet of Things (IoT) is a system that allows sensors, devices, and machines to gather and share data by connecting to the internet. Several industries may benefit from these technologies, including healthcare, agriculture, retail, and transportation. However, IoT in manufacturing is the most crucial and consequential field. This article from Nexle Corporation will explain how the Internet of Things reshapes the manufacturing industry, including its advantages, disadvantages, and trending use cases.
Top 8 IoT Use Cases and Applications in Manufacturing
1. Remote Monitoring Of Manufacturing Operations
Business owners and managers may benefit greatly from having them connected to the Internet of Things to keep an eye on their industrial assets from afar. In this case, the performance may be evaluated using IoT sensors by tracking equipment use and health. If there are any problems, the monitors can also help implement the service. The methodology opens the way for a new business way known as “Equipment as a Service.”
Production line energy expenses were cut by almost 40% thanks to the Internet of Things monitoring system. As a result, Armal has reached the end of its digital journey by implementing an IoT solution for manufacturing for real-time power monitoring of all machines.
One such company that employs molding machinery to produce plastic frames and components is Armal, a market leader in the portable toilets industry. They aimed to monitor and improve equipment’s power efficiency.
They could monitor power use in real-time IoT in manufacturing by installing IoT sensors and industrial IoT software.
IOT technology for remote monitoring of manufacturing operations
With the help of IoT devices for manufacturing, processes may be tracked and equipment settings updated from afar. As a first step, workers may remotely monitor manufacturing operations and validate that their outputs correspond to regulations. Second, remote tuning and configuration let them save time and effort.
In addition, automated devices streamline the monitoring and control of equipment by allowing workers to resolve numerous performance problems remotely using virtual networks. When assets, including mobile ones, are tracked virtually, workers always know exactly where everything is.
3. Predictive Maintenance
Without human supervision, embedded IoT sensors in machines can detect any operational malfunction (regarding temperature, turning number, pressure, voltage, etc.) and alert responsible personnel about equipment deterioration, leaving workers with only the task of repairing it.
Predictive maintenance, or predictive repairing, is a strategy for extending machinery life and lowering operational expenses by identifying potential problems in advance.
To further anticipate when technical support assistance is required, predictive maintenance also enables the integration of Internet of Things (IoT) – connected devices with sophisticated analytics software.
4. Connected Supply Chain
Using IoT in manufacturing, multiple machinery parts may be networked together to boost the efficiency of the production department as a whole. By collecting data in real-time and gaining insights from assets located in multiple factories, this IoT network enables the production department to pinpoint the source of any issues immediately.
In the operations department, the IoT is useful since it helps save expenses by instantly reporting any problems with connected equipment. This reduces the requirement for more staff that is normally needed to keep an eye on the machinery.
Raytheon is a manufacturer of automated systems used for gathering data from manufacturing processes for further analysis. At the Huntsville missile complicated, an Internet of Things device in manufacturing is now analyzing the number of times each screw is turned. If the screw only turns 12 times, the machine will cease operating since it is connected to the Internet of Things and needs to turn 13 times.
Using IoT in manufacturing results in a connected supply chain ecosystem
5. Robotics Automation
While humanoid robots with human-like knowledge and ability may take some time off, the experience required to develop robotization is incredible. The use of advanced mechanics has become commonplace for tedious, high-precision tasks across a variety of production lines. Many benefits could come from using robots for advanced physics:
Maintain a pace of constant production with few breaks
Lessen the possibility of accidents on the job caused by hazardous tasks
Improved skill and productivity thanks to prompt, unprompted leadership
Mechanical advancements have improved, so they no longer need a human manager. They can independently investigate, arrange, and do a growing list of tasks.
6. Supply Chain Management And Optimization
Internet of Things devices in manufacturing keep track of stocks and activities in real-time. With up-to-the-minute data on available resources, manufacturers can keep checks on their supply chain. Work-in-progress details, equipment collection, and raw material delivery schedule are all provided.
When their IoT solutions for manufacturing are integrated with manufacturers’ up-to-date ERP systems, businesses no longer have to rely on paper records of their operations. As a result, the costs associated with mismanagement and a lack of analysis inside the organization are reduced, and the capability of cross-channel data about several departments becomes available to the stakeholders.
IoT in manufacturing may assist with supply chain management and optimization
7. Digital Twins
As the name suggests, digital twins are digital models of real-world objects, concepts, or areas. They are an innovative and effective industry use of the Internet of Things. Even a full 3D representation of the building’s structures may be incorporated, including all of its fixtures, machinery, and structure.
By simulating the impact of potential changes, manufacturers may test them before implementing them physically.
Digital twins – IoT applications in manufacturing
8. Asset Monitoring
It is necessary for businesses to maintain accurate and timely records of their stock and other assets. With IoT-enabled tracking, monitoring facilities is now much easier. This innovation allows for remote asset tracking, which in turn helps you reduce risk factors and achieve progressive revenues.
This IoT-based asset monitoring system’s sensors and devices with GPS or GNSS allow for remote asset management and tracking. These gadgets might be anything from vehicles to kitchen appliances to factory machinery.
Your machine’s performance may be enhanced by analyzing sensor data. Connecting your electrical equipment to the Internet of Things also helps them last longer. IoT sensors actively monitoring the environment may provide consumers with an immediate notification in an emergency. In addition, this streamlines the administration of earlier records.
The SumatoSoft Company was tasked with developing software suited to the client’s Big Data and ML solutions. The company’s primary goal was to enhance the refrigerator-buying experience for customers and monitor any problems. Sumatosoft’s software lets clients keep controls on their fridges in real-time and get notifications if anything goes wrong. In addition, they will have access to past data on repair points, ensuring that problems are not left unchecked for too long.
Energy, materials, and downtime losses are the three main factors that manufacturers deal with. Manufacturers may save money while creating new income streams with the use of the Internet of Things thanks to the listed below:
Optimize asset and inventory management.
Reduce machine downtime.
Increase energy efficiency and agility.
Predictive maintenance and asset and inventory management help companies stop unexpected problems and costs.
Shorter Time to Market
The time it takes to complete a product cycle decreases as manufacturing becomes increasingly quick and efficient. Take, for instance, the vehicle manufacturer Harley-Davidson. With the use of IoT in manufacturing, the company was able to rearrange its York and upgrade its production facility, cutting the time it took to make a single bike from 21 to only 6 hours.
National Safety Council (NSC) estimates the overall cost of accidental injuries at work in 2019 at $171.0 billion. Wage and productivity losses and medical and administrative expenses have been calculated into the total. There are also hidden costs, such as the worth of employees’ time who got involved in the accident but did not get a severe injury.
When compared to other industries, manufacturing has a comparatively higher rate of fatalities and injuries per year. Using the Internet of Things in manufacturing to boost factory safety and reduce accidents is set to remain a popular trend.
With sensors, reliable information on the condition of a building or piece of machinery may be gathered. Potential dangers and risks may also be quickly identified. The following are some examples of how IoT solutions for the manufacturing industry might be used to enhance safety measures:
Wearable devices that monitor technicians’ heart rates and blood pressure. Notifications may be set up to alert users when they are in a potentially dangerous situation while at work.
Smart sensors may send warnings when temperatures, air pollution, radiation, or sound levels are exceeded
Alarms that detect rising temperatures caused by fires
Implement preventive maintenance to decommission or repair unsafe machinery before it can cause an accident or damage
Security and Privacy
Awareness and the security process are essential, and this mindset must spread to every company level. There has been an evolution in recent years toward privacy and security being the top priorities of IT experts. IoT owners worry that the system is at risk of attacks from hackers due to the industrial sector’s popularity.
IoT in manufacturing – Security and Privacy
Smart and secure factories are becoming more necessary as the need for safeguarding against hacking of data and virus (or ransomware) infestations grows. Every part of the Internet of Things needs authentication, from the cloud to the network to the programs running on our computers. Some methods to safeguard the IoT ecosystem are:
Keeping track of real-life IoT devices in manufacturing and preventing them from getting lost or stolen.
Finding risks along with conducting risk analyses.
Making use of encryption.
Machine-to-Machine (M2M) Automation
M2M was first used in manufacturing and industrial settings, where SCADA and remote monitoring were already used to manage and remotely control data from equipment. The main function of M2M technology is to gather data from sensors and send it via a network.
One of the most important things to keep an eye on is the capacity for devices to communicate with one another, and smart sensors may be incorporated into products to make this possible. With the help of sensors, IoT systems can share data and make automated decisions about supply chain management, sales forecasting, and inventory restocking.
Manufacturers that want to use M2M automation should incorporate data collected into company applications. With ERP connecting products and machinery, technicians can track production efficiency and capture insights in real-time. The following are just a few examples of when M2M has been useful:
Asset tracking and monitoring
IoT Blended with VR and AR Bringing Digital and Physical Worlds Closer
The benefits of combining VR/AR with IoT data are enhanced. Profit increases, cost savings, new avenues for current product and service lines, and other monetary benefits result.
Combining VRAR with IoT devices in manufacturing
In 2023 and beyond, the Internet of Things will be an important development to monitor. Some applications that combine AR/VR with the Internet of Things are listed below:
The information gathered by the Internet of Things sensors on equipment conditions may be put as virtual elements to aid in visualizing errors and crashes in real time.
Using AR, factories may better organize stock and design routes that keep employees safe.
Data from the Internet of Things may be used to model real-world machinery or products, facilitating employee training simulations.
Challenges Of IoT Applications in Manufacturing
Managing the industrial Internet of Things technology requires skilled employees. But as the number of smart factories grows, the skills gap between employers and potential workers continually widens. In addition, many organizations struggle due to a lack of upper-level management with expertise in the Internet of Things.
Executives in the industrial sector might find it difficult to make well-informed choices about their solutions if they lack the necessary knowledge, capabilities, and expertise with the Internet of Things.
Employees and management need proper teaching, training, and education in IoT devices for manufacturing and other key technologies if this problem is to be solved.
Areas in which both staff and management have little or no experience include:
Embedded software development
Lack Of Qualified System
A large percentage of workers are not aware of the Internet of Things, according to prominent industry experts. Similar polls have shown that the system requires specialists in embedded data, electronics, Big Data, and Internet of Things security.
Uncertainty In ROIs
Several resources are needed to implement IoT applications in manufacturing, including money for hardware (sensors, gateways), cloud storage, network infrastructure, human resources, and more. Businesses and industries need to consider rapid fixes to see a strong return on investment.
Taking advantage of IoT in manufacturing has an opportunity to reshape this industry totally. Data-driven decision-making, process automation, resource efficiency, and product innovation are all made possible by the Internet of Things (IoT) in manufacturing. Besides, advantages in creating value, customer satisfaction, and competitive advantage might come from using IoT in manufacturing. As a result, the Internet of Things in manufacturing is more than just a tool. It’s a long-term strategy for improving quality and ensuring the business’s continued success.
Nexle is a leading software development company based in Ho Chi Minh City, Vietnam. We are delivering on the world’s largest, most complex projects to transform the way governments, companies and communities work. We have been developing smart, technology-enabled solutions to solve our clients’ toughest challenges, demonstrating a commitment to excellence and a passion for exceeding expectations. Nexle is well positioned to be a partner and co-innovator to businesses in their transformation journey, identify new growth opportunities and facilitate their foray into new sectors and markets. We’re globally recognized for our innovative approach towards delivering business values and our commitment to client success.