by Industrial Internet of Things or IIoT refers to the use of internet-connected sensors and devices to collect and share data from industrial machinery and physical works in order to improve operational efficiency, reduce downtime and maintenance costs, and optimize production processes. By leveraging technologies like embedded sensors, network connectivity, big data analytics and machine learning, IIoT enables real-time monitoring of industrial equipment performance to gain valuable insights for predictive maintenance and process optimization.
Enabling Technologies Behind Industrial Internet Of Things
There are a few key enabling technologies that power the IIoT revolution in manufacturing:
– Sensors and embedded devices: A wide variety of low-cost sensors deployed across industrial equipment collect critical operational data like temperature, vibration, pressure etc which are then analyzed for insights.
– Network connectivity: Technologies like Wi-Fi, low power wide area networks (LPWAN), 4G/5G cellular connectivity provide high-speed, low latency network access to transmit sensor data from remote and harsh industrial environments to cloud platforms.
– Edge and cloud computing: Collected sensor data is processed at the edge for local inferences using embedded systems while large scale analytics is performed in the cloud to derive complex insights.
– Data analytics: Tools like machine learning, predictive modeling, pattern recognition etc are applied on vast amounts of industrial asset performance data in the cloud to gain actionable insights.
– Visualization interfaces: User-friendly dashboards and interfaces enable operators and managers to access real-time operational intelligence and take informed decisions.
Benefits of IIoT for Manufacturing
The use of Industrial internet of things technologies provides several benefits for manufacturers across industries: Predictive Maintenance: By continuously monitoring equipment parameters, anomalies can be detected well in advance, enabling planned downtime for repairs instead of unexpected breakdowns. This significantly reduces maintenance costs.
Remote Monitoring: Remote access to real-time equipment health data through mobile and web interfaces allows proactive oversight of distributed assets from any location.
Process Optimization: Detailed visibility into production line performance using sensor data helps identify bottlenecks, inefficiencies and areas for improvement to maximize output.
Supply Chain Visibility: Tracking shipments, inventory levels etc. using connectivity solutions provides end-to-end supply chain visibility for demand forecasting and reduced downtimes.
Energy Savings: Insights from energy/resource usage monitoring enable targeted initiatives like machine idle time reduction, optimal energy consumption etc. to reduce operating costs.
Quality Improvements: Continuous equipment monitoring helps detect quality issues during production for corrective actions to reduce defect rates and improve end product quality.
Real-world IIoT Applications
Many manufacturing companies across industries are leveraging IIoT to transform operations. Examples include:
– General Electric deployed tens of thousands of sensors to remotely monitor gas turbines, reducing unscheduled downtime by 25%. Sensor data also helped optimize performance and decrease fuel consumption.
– Anheuser Busch InBev installed thousands of industrial internet of things sensors in its breweries for real-time beer fermentation monitoring and quality control. Insights from analytics increased yield by 5% and reduced waste.
– Michelin equipped harvesting machines, tractors and production equipment with trackers to proactively route service technicians, decreasing downtime by 20%.
– Caterpillar uses IoT to monitor construction equipment performance for predictive maintenance alerts through their telematics control units, improving uptime.
– John Deere collects terabytes of data daily from smart tractors and heavy machinery about fuel usage, maintenance needs etc. to boost farmers’ productivity.
– Siemens integrated IoT platform MindSphere collects equipment data from various industries for their Digital Services arm to offer insights-as-a-service.
Challenges to IIoT Adoption
While industrial internet of things presents compelling advantages, certain challenges need to be addressed by manufacturers looking to adopt these technologies:
– Legacy equipment upgrade: Not all existing industrial machinery is compatible with IoT sensors requiring replacements or retrofits, involving capital costs.
– Silos of data: Different systems for various operations lead to data silos, making it difficult to derive plant-wide or enterprise-level insights.
– Scalability issues: Rapid growth of connected assets can overwhelm networks and analytics platforms if not properly architected to handle big data volumes.
– Security risks: Increased connectivity introduces several cybersecurity vulnerabilities like remote access threats, malware attacks on plant systems if not addressed proactively.
– Workforce retraining: Industrial internet of things demands new skillsets like data science, machine learning etc. requiring workforce retraining programs for existing employees.
– Measuring ROI: Quantifying the business value and returns from IIoT initiatives involving soft benefits like improvements in operations is complex.
To overcome these challenges and fully realize the promise of industrial internet of things, manufacturers need to make focused investments in technologies, skills and security frameworks matched to their specific needs and priorities. With the right implementation strategy, IIoT can drive tremendous gains for industrial productivity and competitiveness in the coming years.
*Note:
1.Source: Coherent Market Insights, Public sources, Desk research
2.We have leveraged AI tools to mine information and compile it
About Author - Ravina Pandya
Ravina Pandya, Content Writer, has a strong foothold in the market research industry. She specializes in writing well-researched articles from different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. With an MBA in E-commerce, she has an expertise in SEO-optimized content that resonates with industry professionals. LinkedIn Profile
