How is IoT changing manufacturing

In the ever-evolving environment of the Fourth Industrial Revolution, the Internet of Things (IoT) has now become a key driving force in reorganising the manufacturing sector. IoT has transformed the way industries use, communicate, and operate data. In fact, this has given rise to another movement: the Industrial Internet of Things (IIoT).

The industrial industry is always facing pressure to cut costs and boost productivity, and the Internet of Things (IoT) has shown promise in providing a viable answer to these persistent issues.Indeed, according to 86% of manufacturing executives surveyed by Deloitte in 2019, smart factory efforts will take centre stage in the industry during the next five years.  Another industry report released in 2016 predicted that more than 75 billion devices will be connected by IoT technology by 2025. From optimising processes to improving quality control, increasing productivity, enabling predictive maintenance and streamlining management, IoT technology is transforming the way factories operate. It is anticipated that by 2030, the value of IoT in manufacturing will have increased to $200.3 billion, with a compound annual growth rate (CAGR) of 13.9% from 2021.

IoT consists of a network of physical objects equipped with sensors that collect and exchange data, effectively facilitating connectivity between various machines, systems, and devices. This aids producers in cutting downtime and streamlining workflows. All relevant information and capabilities can be leveraged to develop new revenue and business models. 


Here are some ways IoT can benefit the manufacturing sector:


  • IoT’s role in streamlining production processes


Manufacturers can use IoT to collect data from multiple devices and machines in their factories, which can help identify trends and areas that need improvement.

IoT allows manufacturers to monitor and exchange product status in real time, enabling collaboration between different parts of the production process. Production processes can be easily repeated and production-related issues can be resolved in a timely manner.

Machines and equipment are connected to the Internet, allowing manufacturers to monitor and control them remotely. This data can help you increase efficiency and reduce downtime.

Machines can communicate with each other, allowing production processes to be more efficiently coordinated and streamlined.

By staying connected and informed, manufacturers can reduce unplanned downtime and increase productivity.

IoT enables standardisation of entire production lines and makes it easier to optimise the operations of entire factories.


  • Predictive management possible with IoT


IoT technology allows machines and devices to be connected to the internet, allowing all collected data to be analysed in real time. Potential problems can be successfully identified and corrected to minimise disruption.

Predictive maintenance sensors with IoT capabilities can increase productivity and safety while lowering the Cost of Poor Quality (COPQ). To make sure that machines are running properly, these wireless sensors compute or measure temperature, vibration, acceleration, sound, and displacement frequencies.You can predict with certainty whether your machine will operate in hazardous conditions.

IoT-enabled sensors accurately measure temperature and vibration, predicting potential or existing problems due to changes in standards. These sensors are used in industrial boilers, food and liquid storage, vehicles and conveyors, motors and compressors, robotics equipment and many other devices.

Additionally, manufacturers can use digital twins to digitally recreate bottlenecked production lines and digitally identify and simulate corrections before implementing physical fixes. Modifications and customizations of products are also first tested digitally.


  • Asset and Location Tracking


IoT sensors help manufacturers track their assets, especially moving assets. Knowing the location of your assets saves you both time and money.


  • Optimise quality control


Quality control requires monitoring of a variety of parameters and maintaining consistent product quality is critical to manufacturing. Along with humidity, temperature and air quality also play a big role in the quality of many products. Instead of tracking these parameters manually, IoT now allows manufacturers to track numbers continuously and more accurately. In case of deviations from optimal conditions, the system automatically triggers warnings or adjustments to ensure the product meets stringent quality standards. This helps manufacturers avoid material degradation, microbial growth, high energy consumption, inaccurate results and drying problems.


  • IoT in Warehouse Management


Logistics, or product, material and equipment management, is one of the most important aspects of the manufacturing sector. As manufacturers invest millions of dollars to manage their logistics more efficiently, IoT sensors can help them stay ahead of the competition and prepare for almost any unexpected situation. The biggest challenges in warehouse management include the large volume of products to store and ship, speed of order fulfilment, efficient inventory management and tracking, and rising transportation costs.


Read Also : How much does it cost to develop an IOT app


  • IoT in Security Management


As part of integrated safety systems, some manufacturers have begun using wearable IoT technology. Other working conditions on the job site, such as employee posture, noise levels, gas leaks, etc. may be readily observed and adjusted as needed with IoT technology. This helps improve safety conditions in manufacturing plants.


  • Data Quality and Security


Ultimately, it is important to understand that the true value of IoT can only be realised when data is secure and manufacturers have full control over it. In an IoT ecosystem, various devices and systems must communicate with each other to ensure that information flows smoothly. Forward-thinking manufacturers need to focus on IoT devices and their uses while strategizing how to maintain a competitive advantage.


Read Also : IoT in manufacturing challenges

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