IoT Manufacturing: How IoT in Manufacturing Will Benefit Future Workplaces
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How IoT Works: The Four Factors That Make IoT Possible
The IoT, Internet of Things, is a system of multiple parts such as computers, machines, mechanical systems, and more that send data through a network.
What industries can use IIoT sensors?
Any industry that uses or maintains equipment can make use of IIoT sensors. A few of them include agriculture, manufacturing, and retail.
What are the best metrics and KPIs for manufacturing companies?
Downtime and uptime are the heartbeats of a manufacturer - when the facility has too much downtime, the health of the organization suffers.
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Internet of Things (IoT) technology has become a major part of many facets of modern life, including business. IoT holds an especially significant place in manufacturing, with value estimates reaching up to $3.7 trillion in factories alone by 2025.
In this article, we will cover:
How IoT in manufacturing could revolutionize business
Industrial IoT, or IIoT, promises significant impacts for various aspects of business operations. The following are a few ways in which this technology can transform manufacturing.
Better predictive maintenance
IoT sensors keep a close eye on manufacturing equipment and other assets. When used in conjunction with CMMS software, maintenance teams can track asset data, receive alerts on when predictive maintenance tasks need to occur, and ultimately keep equipment in top running condition. The end results are fewer breakdowns and less equipment downtime.
More automation
In addition to reducing the occurrence of costly downtimes, IoT technology allows many tasks to be automated. Once devices are installed, manufacturers can streamline personnel costs and reduce mistakes from human error.
Less monitoring time
More automation doesn’t necessarily mean maintenance technicians will lose their jobs; however, it does mean that they will be utilized more efficiently. Instead of spending hours out of each day doing routine checkups on equipment, technicians will be able to perform as-needed maintenance tasks based on IoT sensor data.
Quicker time-to-market
With less downtime and higher production rates, you’re able to go from product to market more quickly. On top of that, IoT devices used for asset tracking—such as for packages and shipment vehicles—make sure everything arrives when it is scheduled.
Lower overall costs
The end result of lower downtime, quicker time-to-market, and streamlined processes is reduced costs. You suffer fewer losses, and the efficiency of your processes helps secure higher revenue.
IoT still has challenges ahead
While IoT technology provides numerous benefits to the manufacturing industry, it’s worth noting that there are still some barriers to adoption. Some of those barriers include the following:
Security
One worry revolves around whether IoT technology is actually secure. When public devices are connected to the internet, there is some concern that the system could be easily hacked, potentially compromising sensitive data or locking up processes entirely.
Automation
Another concern is whether automation will cost people their jobs. While IoT will likely take over numerous menial tasks, many jobs will simply be changed by it rather than replaced. Also, given that manufacturers currently have a shortage of skilled labor, this concern may be unfounded.
Upfront cost
Like any new technology, IoT devices often represent a significant investment. The devices themselves may be expensive on their own, and when you add on installation, it can get costly, especially when integrating new technology into outdated systems. While long-term cost savings work out in your favor, there’s still the upfront cost.
Integration time
Along with the initial costs of IoT, integration of new tech into your existing processes and infrastructure can take time. Most integrations are done gradually, asset by asset, process by process.
5 popular use cases for IoT in manufacturing
In spite of the challenges, many companies have already adopted IoT technology. Some of the most common uses the Internet of Things has found in manufacturing include the following:
1. Supply chains
Supply chain monitoring and optimization involves a constant struggle with data. If something goes missing, tracking it down takes thorough investigation into your processes, which is why IoT has become a popular tool in supply chain management. Monitoring a fleet of vehicles or tracking boxes around a warehouse is easy when IoT devices are used.
2. Facility management
IoT provides manufacturers with increased visibility of their facilities and equipment. From controlling building temperatures to monitoring equipment health, organizations are able to keep a close eye on all their processes and head off problems before they develop. Asset health is constantly visible, and any abnormalities trigger an immediate alert.
3. R&D
Research and development efforts benefit a great deal from IoT since it gives research teams access to high volumes of historical data. Each process and asset being monitored has its history fully logged, allowing R&D to draw on precise data when working to improve their processes, equipment, and products.
That data isn’t all internal either. Information on some products and services can be logged from the consumer end as well, with customer feedback providing the backbone for future development.
4. Human productivity
With the automation provided by IoT—especially when monitoring equipment and processes—human workers are able to be more productive. Instead of spending time logging condition data, conducting inspections, troubleshooting, and so forth, maintenance technicians are able to spend more of their time performing repairs and PM tasks.
IoT can also prevent delays by making sure MRO inventories are kept well stocked, performing diagnostic work more quickly, and even automatically generating work orders when maintenance work becomes necessary.
5. Safety
In addition to creating a more efficient workplace, IIoT also helps increase safety. Keeping equipment from breaking down creates a safer place to work.
Workers can also report accidents when they occur, carry RFID tags to keep track of their location, and even wear health monitoring equipment, which can be valuable in industries with potentially dangerous working conditions.
An example of IoT in the workplace
To visualize how IoT can help your facility, let’s look at an example scenario. This particular scenario could apply to any manufacturer.
Efficient use of labor hours
Suppose one of your production lines has ten machines. One of your maintenance technicians checks up on each of those once per week. If it takes half an hour to inspect each one and your technician is paid $20 per hour, that comes out to $100 per week of labor hours spent on inspections.
If you were to start monitoring that entire process with IoT sensors, you’d save $100 per week, or $5,200 per year. That means you’d have over $5,000 to put toward other areas in your business just from that one line.
Additional benefits
In addition to the potential cost-savings offered by IoT, your sensors will be able to detect faults before they occur, prompting repairs before a costly breakdown drives your production to a halt.
In terms of safety, you’ll have alerts before conditions get too dangerous—such as if a boiler starts having issues—allowing you to take precautions as quickly as possible. Given that workplace injuries and illnesses in the U.S. cost up to $225.8 billion each year, that can provide significant benefits to your company.
Combine IoT technology with a world-class CMMS
When used in connection with a CMMS, IoT technology gives you unparalleled visibility of each asset’s health. The following benefits come from using IoT with CMMS software like UpKeep.
Real-time alerts
Getting real-time alerts when equipment conditions cross set parameters allows you to keep on top on maintenance health before it deteriorates.
Audits and insightful reports
Tracking data is one thing, but being able to pull up usable reports is another. A CMMS that allows you to generate custom reports will make your maintenance planning vastly more efficient.
Task tracking
As you use your CMMS to generate and track work orders, you’ll be able to monitor when tasks are completed and make plans to improve your workflow processes.
Final Takeaway
IIoT technology has already had a visible impact on manufacturing, and it will continue to do so as it facilitates equipment maintenance, supply chain optimization, workplace safety, facility management, and R&D.