Integrating Internet of Things (IoT) devices with manufacturing systems helps manufacturers optimize through automation. These devices give managers access to edge processing, predictive maintenance, and real-time asset-tracking to drive performance improvements and make data-driven operational and inventory decisions.
According to McKinsey, these benefits have given the IoT ecosystem a predicted value of over $12.6 trillion by 2030. Manufacturing IoT may provide managers and IT leaders with numerous benefits, but its successful integration presents new obstacles as well, including legacy system compatibility and data integration.
This article provides manufacturing and IT leaders with the steps they need to guide their organization’s successful digital transformation through manufacturing IoT.
Assessing Current Manufacturing Infrastructure
Before purchasing IoT devices, manufacturers should evaluate their system readiness and compatibility. Assessing the current manufacturing infrastructure allows organizations to predict potential issues and needs. With the right assessment, manufacturing IoT can be better optimized for the organization’s current capabilities, limitations, and long-term goals.
1. Legacy System Evaluation
The compatibility of legacy systems should be examined to determine the potential for system upgrades, fixes, or replacements. In some cases, the wireless device vendor can upgrade the current infrastructure. In other cases, full infrastructure replacement will be a more viable way to upgrade the organization’s systems.
A thorough evaluation helps managers identify the scope of the improvements needed. This will help determine whether integration or replacement will be more cost-effective.
2. Integration Points Identification
Identifying integration points is essential to the infrastructure assessment. It allows managers to contextualize their system compatibility with potential IoT devices, including supervisory control systems and other programmable interfaces. By mapping where sensors and data collection points can be inserted, organizations can create a more seamless network between low-level and high-level systems.
3. Technical Requirements Analysis
A technical requirements analysis is essential to avoiding compatibility issues with new IoT device workflows. This analysis should include an evaluation of the organization’s connectivity needs, power restrictions, bandwidth limitations, current data loads, and network protocols.
Developing an Integration Strategy
Once legacy systems have been assessed, organizations must define their strategy for integrating manufacturing IoT device workflows. This involves choosing the right technologies and planning the implementation around the organization’s current and predicted limitations.
Selecting Compatible Manufacturing IoT Solutions
The right IoT device solutions interface seamlessly with a company’s legacy systems. Managers should prioritize platforms with open standards and flexible options for legacy integration. Modern providers use middleware to bridge modern IoT networks with legacy industrial systems. In many cases, this can reduce the need for hardware replacements while updating the network.
Planning Implementation Phases
Once solutions have been chosen, managers will work with IoT providers to plan the implementation process. This can include using pilot programs to test integration before moving on to full-scale deployment. This allows managers to validate the performance of their new networks and gather needed feedback in a controlled environment.
Resource Allocation
Coordinating staff, financial, and training resources with new operational needs requires multi-departmental support. Managers, IT leaders, and department heads must coordinate budget planning efforts to include upfront IoT expenses as well as ongoing maintenance and training costs.
Connecting IoT Devices with Manufacturing Systems
Seamless connectivity is necessary in manufacturing IoT. Managers must guarantee their devices can reliably communicate with the network and with each other, providing real-time performance monitoring and automated device control. To achieve this, manufacturers should review these core processes:
- Communication Protocols: The right communication protocols guarantee the network will remain compatible with new devices. Reviewing common industrial protocols and testing their reliability with existing equipment is essential to seamlessly pairing new IoT devices.
- Data Flow Management: Effective data flow management requires pathways that travel seamlessly from sensors, devices, nodes, gateways, and central portals. Effective IoT providers set the right aggregation and filtering priorities to avoid bottlenecks while the system collects and analyzes performance information.
- Real-time Processing: To effectively respond to operational bottlenecks, manufacturers need real-time data processing capabilities. IoT providers analyze local data constraints to reduce bandwidth load and latency when deploying new IoT systems. Real-time feedback is essential for many manufacturing applications, such as machine condition monitoring systems.
Managing Data Integration and Analytics
Manufacturing IoT can transform new streams of performance data into actionable insights on production, financial, and resource allocation processes. This requires a well-structured analytics workflow supported by reporting tools, including:
Data Collection Methods: IoT devices such as sensors and vision systems can provide real-time data throughout the operating environment.- Processing Workflows: Cleaning, analyzing, and transforming collected data requires time-sensitive processing applications. Modern IoT providers leverage AI to provide in-depth, real-time analytics.
- Reporting Systems: Accessible reporting systems allow managers, leaders, and stakeholders to act on the results of data collection. Visible metrics and real-time reporting functions support strategic planning in a modern manufacturing environment.
Start Your Manufacturing IoT Integration Journey Today
At Allpoint Wireless, our team of experienced IoT device installers recognizes the strategic execution needed to seamlessly transition complex manufacturing workflows to new networks. Our team thoroughly assesses current infrastructure, including its limitations, to develop a phased deployment strategy that includes connectivity testing and analytics trial runs.
Contact our team today to enhance productivity, device uptime, and financial returns through seamless manufacturing IoT integration, even in a rapidly changing industrial landscape.