Production efficiency optimization is the primary goal pursued by every manufacturing enterprise, and Industry 4.0 and the industrial Internet of Things are two important means to achieve the goal. As factories automate data collection and communication, IIoT creates a network of interconnected machines and systems to make factories more efficient and cost-effective IoT improves production efficiency through lean manufacturing, predictive maintenance, and AI integration.
The technology behind the Industrial Internet of Things (IIoT) connects physical processes with internal systems to achieve full visibility of manufacturing operations. Direct links between systems create a smoother and faster workflow from pre-production to customer delivery with virtually zero downtime. These benefits of IIoT are adding value to the industry, which is said to be worth $205 billion by 2022, all thanks to the industry.
The American Institute for Quality surveyed manufacturing companies that had digitized their processes and found surprising results as below:
- Boosts efficiency by 82%
- Forty-nine percent had fewer defects
- Customer satisfaction increased by 45%
How does industrial loT improve production efficiency
Humans still play an important part in manufacturing despite the power of smart factories. As production workers enter the manufacturing digital workplace via mobile communication applications, they can improve production efficiency in the manufacturing process by monitoring any potential weaknesses throughout the production line in real time, remotely monitoring equipment functions and production operations.
1. Inventory management
Knowing where inventory is and having an efficient way to move it, inventory and picking inventory has always been a rite of passage to improving productivity. IIoT solutions utilize sensors to help track the flow of assets throughout the factory warehouse. Autonomous robots can move pick, move products and package orders without human interaction. Employees can focus on other tasks that are more efficient and require more human insight by automating these simple tasks.
2. Predictive asset maintenance
Another impact of loT in manufacturing is asset maintenance. With the help of sensors and RFID, loT can monitor the health of equipment such as tools, smart machines and vehicles and schedule maintenance based on usage. And a number of IoT-based alarm driven systems are included to provide insight into mechanical problems that may need to be replaced or repaired. It not only improves asset utilization but also helps avoid maintenance costs and costly downtime.
3. Field Service
Manufacturers can utilize IoT to provide better services. With sensors and connected devices, businesses can proactively service devices, devices and devices while planning on-site services in a more cost-effective way. IoT solutions in manufacturing also provide visibility into monitoring locations in the supply chain, product status in transit, and delivery schedules.
4. Workforce management
Information from machines, mobile devices and assets can help businesses measure the productivity of employees. Instead of checking employees’ performance, attendance and hours on the factory floor, managers will be able to get a dashboard view of productivity metrics that are automatically updated in real time. This is a turnkey project that includes a loT gateway, wireless sensors, and a portal site that includes data analytics. The platform provides an advanced tracking facility, dwell time detection, and provides complete workforce visibility.
5. Improved procurement and forecasting
Sensors deployed on the production line can help to purchase managers monitor the product assembly, helping to control the raw materials use and reduce waste. They can also send alerts to users when supplies are low. Monitoring these critical items can greatly reduce waste and improve forecasting.
6. Product development
Product development involves an expensive process, but all manufacturers need to go through it to make better decisions before they go into production. Much of the R&D process can be simulated by collecting data from sensors on the high-advanced manufacturing analysis and production floor. Sensors on the product can also be used to collect data on real-world occasions. Gathering the real time data can help engineers make rapid changes for more efficient products.
7. Improve product quality control
Because machinery is already connected to a cloud platform, storing data such as pressure and temperature is easier to track digitally in production batches. Machine vision through high-resolution cameras is another way to track products via production lines. Vision sensors and software can help monitor the quality of products. The technology can greatly help reduce the number of substandard products reaching consumers who may compromise the brand.
Even as more and more loT is used in manufacturing, manufacturers still face some challenges when adopting loT solutions in their processes. Let’s take a look at some of the challenges that every loT application development company has to overcome.
Barriers to the adoption of IoT Improve Production Efficiency in manufacturing
One of the biggest obstacles many application developers face is data interoperability. In traditional manufacturing settings, environmental data is segmented by functional or departmental area. This makes production, scheduling, engineering and quality difficult to relate or compatible with analysis. Note that this situation invalidates the nature of loT, so it is important that the loT application development services handle the migration of legacy systems.
As loT devices and software become common across different manufacturers and industries, there are growing concerns about security. Noting how loT works around business-critical data and equipment in the manufacturing case study, each loT application development company must follow a security-first approach and adhere to all application security best practices to ensure a vulnerability-proof service is provided.
The Future expects of IoT Improve Production Efficiency Manufacturing
Manufacturers could not imagine a future with assembly lines before the industrial revolution. It was this new innovation that changed the face of global manufacturing and improve production efficiency at the time.
The next such innovation is the Internet of Things. If connected systems seemed like science fiction 20 years ago, they will become widespread in the future. We want to collect more data, do more analysis, generate more insights and achieve more efficiency. Manufacturers that accept this reality and utilize IoT to permeate their manufacturing processes will take advantage of these benefits and reap a share of the $19tn in cost savings and expected profits.
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The Industrial Internet of Things is in full swing, and there are a variety of manufacturing solutions on the market. You need professional Internet of Things solution providers and manufacturers to give you the best service. We will help you identify use cases that fit your innovative ideas. If you want to expand your market faster by improving production efficiency, please contact us now to experience the charm of the Industrial Internet of Things.