The Internet of Things is already creating a buzz in manufacturing industry. IoT has grabbed the attention of several manufacturers as it provides supply chain streamlining, timely delivery of data, better top and down management and improved decision making power.
IT/OT integration has the potential to improve the visibility in manufacturing processes to a point where each product unit can be seen at each production process. IoT is indeed the dawn of smart manufacturing.
An informed and smart manufacturing organization contains four elements:
1. Product
Manufacturers use advanced sensors, controls and software applications that work together to extract real-time information. Informed products help the machines to take autonomous action.
2. People
IoT helps in connecting people across all business functions and geographical locations. It provides them with all the relevant information in real-time. Hence, these “informed people” are able to provide intelligent design, operations, higher quality service and safety.
3. Process
IoT enables manufacturers to implement bidirectional information-sharing across the global manufacturing value chain.
4. Infrastructure
Smart infrastructure enables better management of complexities and provides more efficient manufacturing of goods.
Let’s take a look at the advantages of IoT in Manufacturing:
1. Predictive Maintenance
By implementing IoT, manufacturers get notifications for service when it is needed based on predictive analysis. It recognizes the unusual energy usage pattern and automatically delivers proactive information to decision makers. Manufacturers can avoid high equipment costs by fixing the machinery before any failures occur. IoT systems also help in lowering inventory costs and reducing capital requirements. Thus, it improves the quality and maintenance of complex manufacturing processes.
2. Supply Chain Connectivity
IoT lets manufacturers connect the production line to suppliers. It allows all stakeholders to understand interdependencies and the overall process cycles. With IoT systems, manufacturers can have location tracking, remote inventory level monitoring and automatic reporting of material consumption.
3. Asset Monitoring and Management
IoT systems provide a real-time and continuous visibility into location and status of critical assets such as important parts, fixtures, tooling, and goods in transit. Manufacturers are also able to detect off-hours consumption, optimize manufacturing production schedules, and capitalize on opportunities for savings.
4. Energy Management
Energy is considered to be one of the highest contributors of overhead cost for manufacturing facilities. Enterprises are taking several initiatives to minimize energy consumption by focusing on alternative energy sources. Using IoT systems and automation of environmental controls, such as HVAC and electricity, manufacturers can get additional cost savings. Certain IoT systems offer integrated weather data and prediction analysis. It helps the manufacturer to understand the expenses of energy usage.
5. Workplace Safety
Smart manufacturing has not only sped up the factory processes, it has also made the workplace safer for employees. Using IoT systems and applications, users are able to communicate with the workers, operators, and machines in the mine. Also, they can see a real-time view of the ongoing underground mining operations and immediately inform the workers if any hazardous situation comes up.
In future, manufacturers are expecting more data to be analyzed using IoT. IoT has provided manufacturers with operational efficiencies, accurate insights and a competitive edge in the market.
All manufacturers are now learning to accept the importance of IoT and allowing it to permeate into their processes.
by Naveen Joshi