The Internet of Things (IoT) has transformed the manufacturing sector with key data-driven features, such as real-time monitoring and predictive maintenance. IoT-enabled systems present opportunities to optimize production efficiency and reduce costs by supporting and streamlining modern manufacturing processes.
This article covers IoT use cases in modern manufacturing processes. IoT manufacturing is a trend that will continue to redefine how manufacturers track assets, implement predictive maintenance, and streamline communication in their industry for years to come.
IoT’s Role in Modern Manufacturing
Accurate, precise, and fast robotic assistance has become a staple of modern manufacturing. The next logical step for automation in manufacturing is to revolutionize how machines communicate with each other, share data with the business, and automatically coordinate their processes. IoT sensors and other systems hold the key to these processes.
Key IoT Components
IoT systems operate by communicating between four layers of functions: a perception layer, a connectivity layer, a processing layer, and a user interface layer.
- The perception layer includes sensors that acquire external information that feeds into the system. To use a common example in manufacturing, automated humidity controllers are equipped with sensors that feed data to the air quality control system.
- The connectivity layer connects these sensors to other IoT-enabled systems via network gateways, which collect sensor readings from multiple applications. These readings are processed in the next layer, which analyzes the performance data.
- The user interface is the top layer where human administrators can interact with the results through a centralized dashboard.
Core Benefits
IoT devices enhance manufacturing operations by reducing downtime, increasing process efficiency, and improving product quality. According to Statista, businesses across industries now deploy over 100 million IoT-integrated devices, spurred by their growing use cases in everything from manufacturing to retail.
Implementation Considerations
Seamless connectivity is the primary concern when implementing IoT devices. Businesses should focus on the primary pain points of modern manufacturing: complexity, speed, capacity, and cost, to monitor their workflows for improvements using IoT-enabled systems.
Additionally, all IoT system implementations should account for systems on the current network. Everything from the POS to the inventory management system should be able to communicate through IoT devices and share data on the central hub.
Real-Time Monitoring and Data Collection
IoT manufacturing devices monitor and collect data in real time to facilitate scalable modern manufacturing processes with these key factors.
Sensor Technologies
Advanced sensors are the benchmark for IoT applications in manufacturing. They can monitor equipment operations, failure indicators, and more through observable metrics such as:
- Temperature
- Vibration
- Humidity
- Energy consumption
- Air quality
- Device downtime
Equipped with these sensors, robotic IoT systems can monitor production quality more quickly and accurately than human workers, reducing manufacturing deviations, avoiding recalls, and improving the customer experience.
Data Analytics
This information is processed to generate actionable management insights. IoT connectivity enables real-time data transmission and analysis, guaranteeing that the machines analyze the latest performance trends using current data output.
Actionable Insights
With significant real-time performance data available, manufacturers can make more informed decisions about workflow productivity, resource allocation, and more. Centralized IoT communication enhances manufacturing visibility at all levels, from location tracking to maintenance.
Process Optimization and Efficiency Gains
IoT systems provide key benefits specific to process optimization in manufacturing, including:
Automated Workflows
IoT-powered automation streamlines manufacturing workflows by automating repetitive tasks. This reduces the chance of manual errors and improves production speeds through continuously operating wireless systems.
Quality Control Improvements
With IoT-enabled performance sensors and centralized monitoring tools, manufacturers can detect defects earlier in the production process. This allows them to minimize waste, reduce the risk of recalls, and improve their customer satisfaction scores.
Resource Management
IoT manufacturing tools optimize energy consumption, raw material consumption, and workforce allocation workflows. They create actionable plans backed by real-time performance data specific to each business, enhancing resource management for its specific needs.
Predictive Maintenance and Downtime Reduction
With IoT-enabled sensors automating performance, condition, and quality monitoring tasks, businesses can predict and address equipment failures before they occur. This predictive maintenance allows manufacturers to reduce costly downtime and lower maintenance costs by reducing equipment breakdowns by as much as 70%.
Cost Savings and ROI Analysis
By centralizing data processing and automating repetitive tasks, IoT devices can optimize supply chains, improve production speed, and facilitate delivery processes. Each of these leads to cost savings that feed back into the business’s automated ROI analysis. IoT systems continuously conduct performance monitoring reviews to provide managers with updated data on the ROI of their new processes and how they can better hit their targets.
Transform Your Manufacturing Process with IoT Solutions
Growing order processing speeds in increasingly competitive sectors means many manufacturing businesses without automated data organization are struggling to provide faster delivery and lead times. The immense volume of product orders often strains their traditional supply chain workflows.
IoT manufacturing solutions can transform key processes by automating repetitive performance monitoring tasks, collecting and analyzing performance data, and centralizing data-driven insights into one accessible dashboard. Our team at Allpoint Wireless provides wireless IoT-enabled devices, SIM card options, and data plans to bring manufacturing workflows into the 21st century.
Contact our team today to learn about our financing options and device features to find the perfect IoT solutions for your business.