REASONS FOR NEED OF IoT IN MANUFACTURING PLANTS

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IIoT enabled industry 4.0 and smart manufacturing. It is widely adopted by manufacturing companies to gain productivity improvements and uncover new ways of enhancing manufacturing operations. It allows manufacturers to collect data from different sensors and analyze them to improve their production as sensors can measure when production output is compromised. It allows manufacturers to check the equipment for accuracy with the help of sensors alert. It allows companies to get better uptime, improve asset performance management, management of resources and reduce operating cost. For example, if there is a fault in the engine, sensors will send data to a common IoT platform which will allow it to communicate with manufacturers. He will track the manufacturing plant of that engine and rectify the issue with the manufacturing belt.

Reasons why we need IoT in manufacturing are –

Smart factories

Manufacturing plants are rapidly adopting the smart factories as it provides the benefits such as:

·    Increased performance

·    Better control of product life cycle

·    More efficient safety

·    More responsive smart environment

IoT established a connection between the companies, manufacturers, employees involved in product design and development, and supply chain managers. Such a connected factory is cheaper to maintain and faster to manage. IoT and smart manufacturing devices alert manufactures if there is any unusual activity such as high or low temperature happening that can put the manufacturing tools in jeopardy. It improves the speed and quality of the maintenance. IoT also helps in inventory management as it allows tracing all the materials needed for manufacturing on item-level.

Predictive Maintenance

Manufacturing companies spend millions of dollars in operational and maintenance costs. To avoid the failures of equipment in mid production, industrial IoT facilities like sensors, data, and analytics in equipment acts as an aid as they help manufacturers to avoid overloads, bottlenecks during the production process that could lead to equipment deterioration. It helps to easily detect and predict failure before it occurs.

Cost reduction

The data sent to IoT platform is studied using advanced analytics, AI, machine learning which helps in developing a well-defined maintenance strategy. The analyzed data reduces unplanned maintenance costs by making adjustments during run time. It has helped the manufacturing companies to reduce the maintenance costs by 75%. Also, the traditional method of hiring many workers to handle manual tasks is expensive. IoT helps in automating the processes, so it can reduce the need for a good portion of staff resources.

Quality control

Product development and its quality is an important factor of manufacturing industries. The IoT controls it on each stage by tracking the quality of materials, manufacturing environment, temperature, the amount of waste created per product and so on. The plant manager gets the detailed reports regarding each step of product manufacturing, transportation, and distribution of ready goods. All this data allows managers to find the loopholes and improve the quality of product, equipment, workflow, and environment, or the vehicles used for transportation.  

Safety

IoT in manufacturing helps in the safety and security of the site and employees. Machine malfunctioning results in workplace accidents, so the volume of data processed by IoT about the equipment makes it easier to identify defective machines and work on them before they pose health issues. The IoT technology can track the environmental properties to ensure that dangerous chemicals are not released in the air.

Plant security management

Security features such as security cameras, locking doors, motion detection (alert users when detects any activity) can notify a manager in case of any foul play, equipment and property damage.

Supply chain optimization

Devices with IoT help the manufacturing companies to track products as they move through the supply chain. Devices are “tagged” so that manufacturers could manage, track, inventory them and be able to trace back to the cause of a delay as all the interdependencies are tracked.  Tagging of devices is done through technologies such as barcodes, digital watermarking, and QR codes Radio Frequency Identification (RFID) is used in barcode detectors for the supply-chain management domain that allowed accelerating the process of data transfer directly between devices with no human involvement.

CAPTEURIO provides you with an end to end IoT solution with constant service so that you can relax while our devices does the job of monitoring your critical assets. We provide live data monitoring, reports, real time alerts, maps, user management and more.

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  1. Pingback: Temperature monitoring in depth analysis

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