Learn About The 5 Best Use Cases of IoT in Manufacturing

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Why is the Internet of Things gaining so much traction?

A few decades ago, the idea of embedding sensors and processors into physical objects would sound insane and hopeless. However, thanks to the Web of Things that it became real. This technology has grown into the prime notion for many businesses within a brief span of time. The Internet of Things has considerably changed some parts of our everyday life such as driving, cooking, purchasing, manufacturing etc..

A handful of IoT devices are springing up nowadays. Consequently, the amount of IoT-active devices excluding smartphones, tablets, laptops is very likely to grow to 8.3 billion by the end of 2019. Moreover, the amount of Internet of Things units in different businesses will come to 29.7 million units by 2025.

Speaking in numbers, the vulnerability of IoT is quite impressive:

Many worldwide enterprises have successfully integrated IoT tools into their infrastructures. It allows them to maximize the manufacturing process, reduce delivery time, and reduce the costs. All this makes the IoT market share boost exponentially during the next few years. And while IDC reports the IoT footprint is expected to grow up to $1.2 trillion in 2022,

IoT in manufacturing: the benefits explained

With all that said, it is no wonder that the Web of Items in manufacturing is beneficial both for the manufacturers and for their target customers. Industrial IoT enables manufacturers to scale up different equipment capable of distant observing and servicing. As a result, companies can have a right estimation of customers demands.

Manufacturing as one of the industries is taking up the prospects of the Internet of Things. A variety of plants are already utilizing connected control methods for procession and supervision. The main benefits of IoT solutions are as follows:

It aids in detecting and avoiding the issues that may cause delays.

With cognitive operations, the industrial unit can increase manufacturing quality and rip the benefits from raw stuff, and manufactured parts.

In addition, it gives managers an opportunity to allocate the resources, improve worker skillfulness and make the working environment safe.

View a potential scenario of how the IoT system can help an employee in manufacturing at a short video below.

Currently, many IoT jobs deal with facility and asset management, security and operations, logistics, customer servicing. Which is the reason, IoT is a promising tech fad, if not a mainstay for business in 2020 and beyond. So, let us take a deep dip into the very best IoT examples in manufacturing.

Predictive Repairing

Predictive Maintenance IoT in Manufacturing

Through connecting IoT-driven gadgets that have different sensor issues (temperatures, vibration, voltages, currents, etc.) to other devices, IFTTT, cloud/API or legacy systems manufacturers can obtain essential maintenance data. This sort of information allows us to estimate the current state of machinery, figure out warning signals, transmit alerts and activate corresponding repair processes.

This way IoT transforms maintenance to a fast-paced and automated practice, which foresees a failure extended time in advance. What’s more, it fosters cost savings over traditional preventive measures as the actions are taken exactly when they are necessary.

Getting valid data in time, managers can discover plant machinery that needs fixing. Besides, it can help to plan maintenance operations completely and hold systems on the internet as workers are still performing the task. IoT may extend equipment lifetime, bring about plant safety and lower the risks of accidents that affect the environment negatively.

In simple terms, IoT can immensely improve your company’s predictive repairing/maintenance capabilities. For example, one of the leading international manufacturers of medical gear, Medivators, successfully integrated IoT solutions across their worldwide services to enjoy an impressive 78% boost of the service events and issues that can be easily controlled and (if there is a case) fixed without any additional manpower resources demanded.

Remote Manufacturing Control

Reallocating your company’s computational resources to a custom cloud or connecting the device to a few of the popular BAAS (backend as a service) or even PAAS (platform as a service) cloud computing models, you can collect and analyze the large-scale data sets necessary for supervising various field devices such as switches, valves, and other indication elements.

Thanks to IoT this data is transmitted to the industrial automation system that ensures an overall control of machinery amid the manufacturing process. Telecommunications, oil and gas industries, as well as power generation, have been already reaping the benefits from IoT devices implanted into distant control methods.

The most prominent feature of remote production control in industrial automation systems is the centralized supervision over the machinery in the process of manufacturing. Information obtained via distant control provides a much clearer and faster insight to the actual manufacturing field. It gives assistance to the staff in analyzing the enterprise data.

All this makes the IoT technology become a core instrument in ensuring safe automated production, tracking the workers, tracking the personnel location.

Asset Tracking

More and more manufacturing enterprises have a tendency to execute asset practices. IoT technologies together with the progression of native internet and mobile apps for iOS or Android makes it possible to obtain real-time asset information and make reasonable decisions.

The major task of tracking lies in discovering and overseeing such crucial assets as the components of the supply chain (raw materials, containers, and finished goods). Such applications can drastically maximize logistics, maintain stocks of work in advance, and disclose thefts and violations.

IoT-based asset tracking helps the producers calculate the usage of movable equipment elements and initiate measures to shorten idle interval and enhance utilization.

Logistics Management

Enterprises that depend greatly on transportation can also benefit from IoT-led interconnection between various devices and systems.

Managing the automotive fleet via IoT-driven apparatus helps manufacturers eliminate or put down the risks regarding the expenses related to vehicles, staff and transportation. Autonomous fleet solutions promote the greater efficiency of the company.

Logistics managers make good use of leveraging IoT when it comes to repairs and fuel expenditures. They optimize their tasks that pay monitoring fuel expenses, smart deliveries, diagnostics, and drivers.

Furthermore, a real-time neglect of driver and vehicle performance aids to raise technicians’ safety, bring down stock damage and decrease insurance payments.

Digital Twins

Applying the IoT approach, known as Digital Twins, lets businesses create and revel in the strong digital copies of the physical items manufactured by a company. When enabled by IoT, a POC (proof of concept), an MVP (minimum viable merchandise ) or a look and feel prototype turn out to be so accurate that you can easily experiment and foresee their functionality as well as initial and final operational capabilities.

This type of IoT application area allows simulating a lifespan of machines, checking updates, and forecasting potential issues and bottlenecks. With IoT tools, producers can get a replica of equipment and products for tracking them into a virtual environment before placing them to market.

Finally, it improves product quality, creates efficient distribution and delivery chains, opens new opportunities for businesses and brings customer service to a higher degree.

Explore how digital twins maximize the manufacturing process and eliminate any bottlenecks in the production lines.

Either way, getting the IoT solutions implemented in your business processes requires solid expertise in this field.

Design Leader in 4i Platform - Company specialized in Industrial IT solutions.
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