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IoT in Manufacturing: Enhancing Operational Efficiency

Posted on 21/05/202008/06/2021 by Anteelo Master

Smart factories are now a reality. IoT is building a new manufacturing landscape by connecting automated production technologies and smart manufacturing processes.

With every passing year, advanced methods and equipment enter the manufacturing space to take production capabilities to the next level. This year-on-year maturing of technological advancement is what has brought us from the first industrial revolution to the 4th industrial revolution.

The current revolution that industries are operating in, comes with its own unique set of methodologies and technologies. It is redefining operational efficiency.

While the previous revolutions worked around the specific areas of the industrial sector, the fourth industrial revolution comes powered by the ability of connectivity. In this article, we are going to look into the many aspects of how is IoT transforming manufacturing and the many challenges the sector will have to overcome to become a part of the future of IoT in manufacturing.

Welcoming the Fourth Industrial Revolution

In order to understand the true Internet of Things applications in manufacturing industry, it is necessary to look back at the industrial revolutions. Ever since the 1700s, there have been 4 revolutionary shifts in the manufacturing sector.

The first – water power was introduced for increasing efficiency of steam engine based machinery like cotton gins, loom, and conveyor, etc.

The second – emerging in the 1870s, the second industrial revolution brought us electricity. The invention of the power stations and bulbs powered factories’ automation and gave birth to the concept of mass production.

The third – emerging somewhere around the 1960s, the third revolution introduced digital technology and computers, replacing analog technologies. The phase opened the world to globalization and increased trade.

The fourth – this is the era of cognitive manufacturing. In the ongoing phase, big data, IoT sensors, robotics, and predictive analytics will merge to form a brand new definition of IoT in industrial manufacturing operations.

The fourth industrial revolution presents a glorious age for manufacturing and industrial space. Businesses are beginning to understand the massive impact of IoT in the production process, they have started initiating talks with every sound IoT development company to figure out the way to harness the IoT use cases in manufacturing. As a result of their interest, the technology is reciprocating with a number of use cases of IoT solutions in manufacturing.

How is IoT in Manufacturing Changing the Sector’s Landscape?

With IoT implementations in manufacturing becoming a new norm, there are a number of benefits manufacturers are looking to derive from the combination. Let us list down some of the most promising benefits of IoT for manufacturers.

1. Inventory management

Through the linking of equipment like smart totes, smart shelves, forklifts, etc with wireless communication and RFID, sensors, manufacturers would be able to maintain a real-time view of an inventory. On the production level, sensors linked to bins and machines will be able to provide real-time data on inventory consumption and notify the need for re-ordering or automatic refill.

2. Predictive maintenance of assets

Another impact of IoT in manufacturing industry can be seen through the role of technology in asset maintenance. With the help of sensors and RFID, IoT can monitor tools, smart machines, and vehicles, etc for equipment health and then schedule their maintenance on the basis of usage.

There are a number of IoT-based alerts driven systems that provide insight into mechanical problems that could warrant replacement or repair. It doesn’t just improve asset utilization but also helps avoid expensive downtime maintenance expenses.

3. Field Service

IoT enables manufacturers to better their capabilities as a service provider. Through sensors and connected devices, businesses can perform proactive servicing of appliances, equipment, and devices while planning field service in a more cost-effective manner. IoT solutions in manufacturing also offer visibility in the supply chain for monitoring locations, the state of products in transit, and the delivery schedules.

4. Workforce management

Information from assets, machines, and mobile devices can help businesses measure the employees’ productivity. Managers will no longer have to walk the factory floor and see how their workers are performing, they will be able to get a dashboard view of productivity measures created automatically and updated in real-time.

An example of the workforce management specific manufacturing IoT use cases can be seen in the COREIoT Workforce Management solution. It’s a turnkey project which comes with a 4G IoT gateway, wireless sensors, and a web portal that includes data analytics. The platform offers an advanced tracking facility with dwell time detection offering complete workforce visibility.

5. Quality assurance

An active role of IoT in manufacturing can be seen in the ways quality initiatives get added to the operational processes. The technology can help highlight variation in product flow and in the pre-decided guidelines set for measuring product specifications.

The result lies in improved efficiency on an overall level since products are developed according to specifications, defective production is stopped in real-time, and repairs are conducted to prevent system and equipment downtime.

6. Cognitive operations and processes

The idea of cognitive operations lies in the ability to take present data and analyze it for driving decisions around better operations, safety, and quality. A system linking technology like IoT can help analyze both structured and unstructured data like video or photos, bringing greater certainty to business operations and decision-making. Here are the different ways that help –

Better productivity of production line
Speedy repair and service call which lowers warranty costs
Improved quality.

7. Optimization and smarter resources

The last point in our list of benefits of IoT in manufacturing revolves around optimizing resources – energy, people, knowledge, and equipment. It is essential to follow the best optimization practices for keeping the cost low and bettering the overall productivity and engagement levels. With the combination of cognitive insights and IoT, it becomes possible to use data like usage, geolocation, environmental conditions, etc. for:

Better worker safety and effective workforce management
Improved worker productivity and expertise
Reduction of energy consumption by equipment and buildings.

Even amidst the growing use of IoT in manufacturing, there are some challenges that manufacturers face when it comes to the adoption of IoT solutions in their processes.

Let us look into some of those challenges that every IoT application development company has to overcome.

The Barriers to IoT Adoption in Manufacturing Sector

Interoperability of data

One of the biggest barriers that IoT app developers face is in terms of data interoperability. In the traditional manufacturing setup, the environment data are siloed according to functional or department areas. This makes it difficult for production, scheduling, engineering, and quality to be linked or be compatible for analysis. Noting the situation which nullifies the essence of IoT, it becomes very important for IoT application development services to take care of the migration of legacy systems.

Lack of IoT Skillsets

IoT is still at a developing stage, meaning employing someone with the expertise in leveraging IoT and performing its successful deployment remains a challenge. What makes the matters worse is that when we look into IoT adoption in the manufacturing space, it is not just the technology’s skillset which is required but also experience in analytics, big data, embedded software development, and electronics, and IT security, etc.

Instances of data breach

With IoT devices and software becoming common across a range of different industries and manufacturing there are growing concerns around their security proofing. Noting how IoT in manufacturing case studies works around business-crucial data and equipment, it is essential that every IoT app development company follows a security-first approach and abides by all the app security best practices to ensure a breach-proof service.

Initiate Your IoT in Manufacturing Journey With Us

Entering the sector which still has one leg dug deep in the traditional methodologies can be a challenge. As a tech-forward entrepreneur, you would need help from IoT developers who have worked with manufacturing industry stakeholders. We are here to help you.

We can help you identify the use cases that apply to your reformative idea, the process you will have to follow to counter migration issues, and how to find the best product-market fit. If you are a manufacturer struggling with similar issues or something new, reach out to us.

What is IoT? The internet of things explained

Posted on 03/03/202015/06/2021 by Tushar

Suppose you are going for a meeting to a nearby town. While traveling, a message popped on your device screen informing that the volume of petrol is going low. You were confused about what’s happening, when another message sharing the details of a nearby petrol station popped up on your smartphone device. Wondering how is that possible? Well, it’s nothing but a real-life example of IoT.

Confused about what is Internet of Things (IoT)? How does it work?

Let’s talk about it in detail in this article – starting with some exciting statistics.

Statistics Proving the Uprising Market for Internet of Things (IoT)
A Brief Introduction of Internet of Things (IoT)
Working of IoT Technology
4 Major Components of IoT Ecosystem
Ways IoT is reshaping Business world

Statistics Proving the Uprising Market for Internet of Things (IoT)

By 2019, the global IoT market will generate a revenue of $1.7T.
By 2022, 100% of the population is predicted to have LPWAN coverage.
By 2025, there will be more than 75.4B Internet of Things devices worldwide.
In 2018, there were around 7B IoT devices. However, more than 10B devices are expected to join Internet of Things ecosystem.
As of 2018, nearly half of all IoT (Internet of Things) devices were connected to WPAN (Wireless Personal Area Networks), including Zigbee, Bluetooth, and Z-wave.
54% of Enterprises invested in IoT app development because of its cost saving factor.

Now as we have taken a glimpse of IoT Trends 2020, let’s begin right from the basics.

A Brief Introduction of What is Internet of Things

IoT, also referred to as the Internet of Everything (IoE), is an ecosystem of interrelated computer devices, digital machines and objects that has the ability to transfer data to each other in real-time, with minimum human intervention.

These devices include coffee makers, washing machines, music system, TVs, wearables and other electronic devices that can communicate with each other using what is called Machine-to-Machine (M2M) communication.

While this is all about what is IoT technology, let’s turn towards its working mechanism.

Working of IoT Technology

When talking about how does IoT work, the process begins with devices that have built-in sensors. These devices are connected to IoT platforms which stores data from all the connected devices. The important data is then used to perform tasks that fulfil the needs of people.

When we say the data is stored in the IoT platforms, it doesn’t mean that all the data is useful. Devices carefully select only particular data that is relevant to execute an action. These pieces of information can detect patterns, recommendations and problems before they occur.

In this way, IoT application works with smart systems that automate tasks to address specific needs.

However, if you still have any doubts regarding how does it work, check out this video:-

With this attended to, let’s dive deeper into IoT market and see what are the prime components of Internet of Things technology.

4 Major Components of IoT Ecosystem

1. Sensors/ Devices

The foremost component to consider in Internet of Things technology is sensor/devices. A sensor picks up all the minute details from an environment. The environment can have many complexities. What makes IoT security so great is these sensors that pick up even the most sensitive changes. These sensors are built in the devices which collects all the data to be used later. For instance, our phone is a device with built-in sensors like GPS, camera, etc.

2. Connectivity

Once the data is collected it is transferred to the cloud infrastructure (also known as IoT platforms). But to transfer the data, the devices will need a medium. That’s when connections like Bluetooth, Wi-Fi, WAN, cellular networks, etc come into play. These mediums are all different and must be chosen wisely for best results.

The effectiveness IoT security highly depends on the speed and availability of these mediums.

3. Data Processing

After reaching the cloud infrastructure the data has to be analysed so that the right action can be taken. This process is however considered one of the most crucial obstacles in front of IoT app development. The analysis can be as simple as checking the temperature of the AC or a complex one such as a situation where an intruder comes in and the device has to identify it through cameras. The IoT application is made such that it can process all the data at a fast rate to take immediate actions.

4. User Interface

The last step is when the user is notified about the action with the help of a notification or an alert sound sent to the IoT mobile apps. This way the user will know that his command has been run through the systems.

However, this isn’t as easy as it seems. It all depends on what is IoT platform and how the technology has been developed. It becomes crucial for Internet of Things (IoT) app development companies to develop a system that can also be manually adjusted. In a situation where the temperature of the fridge is not cold enough to freeze ice cubes, users should be able to do that manually without the system backfiring.

Now as you have gained an insight of what this technology is, let’s take a look at what are the uses of Internet of Things in the present world – besides backing the concept of Smart Homes and cars.

What IoT Means to the Business World

1. Healthcare

IoT in Healthcare has opened new doors of opportunity for medical specialists and patients. The technology enables doctors to get a real-time access to patient medical data, store them on cloud, and share with others. It also cut down the waiting time, helps to check for the availability of hardware and equipment, and simplifies the process to identify chronic diseases and take the right actions to mitigate the risk.

2. Education

Internet of Things technology is also revolutionizing the education sector. It is connecting people worldwide to ease the process of sharing knowledge, reduce the barrier in gaining access to any data, introduce security in education system, and more – a glimpse of which you can take from the video shared below:-

3. Retail

Another domain that is enjoying a myriad of opportunities and facilities after getting an understanding of what is Internet of Things and how to incorporate it in their processes is Retail.

The industry, with the help of what we call as Internet of Things applications, is finding it easier to deliver personalized experience to their user base, automate checkout processes, perform maintenance effortlessly, and more.

4. Sharing Economy

The combination of IoT and Blockchain, i.e, (Blockchain of Things) is reshaping the Sharing economy. The dual technologies are helping to build an online marketplace where data from all the companies and stores can be stored and shared securely and effectively using the concept of Smart Contracts. And eventually, used by others with the motive to cut down the efforts required from the user end.

5. Real Estate

IoT technology is also reshaping the real estate economy by speeding up decision making process, offering more energy-efficient options, making space smart, and more.

6. Travel

Here, IoT is empowering travel agencies to deliver real-time information, automate most of the processes, and send electronic key cards on guests’ smartphone. And in this way, adding convenience, ease and security to their experience.

So, as we have covered so far in this article upon what is Internet of Things, the technology has a wider scope in almost every business vertical. But, if you still have any doubt or wish to design an IoT-based solution for your business, connect our IoT mobility experts today.

How the Iot is Shaping modern Business in the 21st Century

Posted on 29/01/201919/06/2021 by Tushar

The world is getting smarter. Every day, devices and modern technologies that were once standalone are getting connected to the internet. From robots to running shoes, these smart devices contain sensors that allow them to be monitored and controlled remotely and to gather large quantities of data. Collectively known as the Internet of Things (IoT) these devices are transforming modern business. Here, we’ll take a look at how.

What is IoT?

The IoT is a system that comprises the smart devices deployed by companies, together with the infrastructure and applications needed to connect, monitor and control them and to gather and analyse the data they generate.

In most cases, IoT systems are automated so that processes can be done with little or no human intervention. This often requires the use of cloud-based technologies, such as real-time analytics, artificial intelligence and machine learning. By adopting such modern technologies, highly complex operational processes can work smoothly while employee involvement can be radically reduced.

Today, IoT systems are used everywhere. Domestically, they are used by consumers to manage their homes: controlling lighting, heating, security cameras, etc., via their phones and smart speakers. Businesses and other organisations use them for a much wider range of purposes: logistics management, server monitoring, remote automation, personalisation, energy management, remote workforce monitoring and much more.

Here are some of the main ways the IoT is having an impact.

Inventory management

Inventory management is traditionally a time-consuming, labour-intensive process. The complexities of managing inventory mean data is rarely accurate or up-to-date and this often causes difficulties with procurement and order fulfilment.

Today, goods are labelled with RFID or Bluetooth tags and these are scanned automatically by IoT-connected scanners on entry to and exit from the warehouse and during transit. The scanners don’t just calculate stock levels, they also record the item’s location (making it easier to deploy warehouse robots, like Amazon) and the dates and times of movement.

Companies which use this modern technology always have accurate, real-time data about stock levels and can quickly find products in the warehouse. What’s more, the system can report issues with stock shortages, shelf-life, temperature control, travel delays and even flag potential theft from staff. On top of this, the company can be notified which stock items are in short supply and those which aren’t being sold, helping them make better decisions about procurement, product choice and pricing while ensuring that accurate fulfilment details are available.

Customer experience

The customer experience is a critical element of the modern marketing strategy, with companies going all out to satisfy the ever-increasing expectations of the consumer. Those that succeed benefit from enhanced brand loyalty and significantly increased customer lifetime value.

IoT plays a key role in enhancing the customer experience as devices are used to gather customer information from every available touchpoint. Data from mobile apps, social media interactions, home devices, customer communications, website browsing and sales histories are unified to glean insights that provide personalised customer experiences which meet the needs of the user.

Productivity

Sensors built into devices gather data that help companies drive up productivity in all areas. From production line processes to shipping delivery routes, operations and tasks can be completed quicker, more effectively and more cost-efficiently. Employee workloads are also reduced and the potential for automation is increased, enabling companies to reduce staffing levels or increase production.

Remote work and operations

IoT enables organisations to undertake remote working at levels previously inconceivable. An example which perhaps illustrates this best is the da Vinci robotic system, used by surgeons to carry out remote operations on patients. The surgeon views the patient in real-time while the connected robot holds the instruments and mimics their hand movements. Another advanced example is the real-time monitoring of aircraft engines during flight which enables specialised technicians to remotely deal with any issues that may arise.

On a less advanced level, IoT technology helps owners run their businesses or operations from anywhere in the world. During the lockdown, numerous companies have relied upon remotely connected devices to help employees work from home. Businesses that work on the go, such as plumbers, electricians, broadband installers, delivery drivers, etc., have been using IoT devices for a long time, helping them maintain schedules, track productivity, order and collect equipment and parts, obtain customer signatures and so forth.

Data-driven insights

IoT technology enables far more data to be gathered. That data can be analysed using advanced analytics programs, together with AI and machine learning, to provide previously unobtainable insights into the business. These can be used to improve efficiency, productivity, marketing and communications strategies; to predict market movements and forecast supply and demand; and to monitor machine health and improve security. When data is gathered from devices used by customers, the insights can be used to develop better products, offer better services and better meet the customer’s needs and expectations.

Conclusion

With so many connected devices for businesses to deploy, and with the infrastructure needed to make use of the IoT readily available in the cloud, IoT adoption is becoming increasingly popular amongst the business community. Its potential to bring improvements across so many areas of business operations is making it a technology hard for business owners to ignore, regardless of the industry they work in.

Ways how IoT can be an asset for businesses

Posted on 06/10/201819/06/2021 by Tushar

IoT devices enable businesses to generate large volumes of valuable data. This real-time information gives them a better insight into their performance, helping them to be more productive and efficient and have a better understanding of their customers while opening the door to innovation in workflow and new services. Here weâ€™ll look at seven ways businesses can benefit from the IoT.

1. Asset tracking

The tagging of items using inexpensive Bluetooth or RFID tags and the use of internet-connected readers to track them means almost any asset can now be connected to the Internet of Things. This enables companies not only to know where all their assets are but also to check their usage, maintenance history and, in some industries, an assetâ€™s health.

Preventing assets from getting misplaced can improve efficiency and cut down on unnecessary repurchases. In sectors like healthcare, where critical equipment can be located across a hospital, it can be life-saving. The ability to check usage and maintenance ensures compliance with regulation and helps companies understand when assets need upgrading. The monitoring of asset health is critical in many industries and can help prevent manufacturing processes coming to a complete standstill or, as in the case of inflight aircraft engine monitoring, prevent catastrophes.

2. Inventory Tracking

Tagged inventory can also be connected to the internet using the same Bluetooth or RFID technology, giving companies real-time stock level data. This can reduce the cost of manual stock taking while providing more accurate, up to date information. This provides much better inventory management and, as it is connected over the internet, can be used across multiple sites. It is ideal for retailers and for the manufacturers, wholesalers and logistics companies that serve them.

Indeed, using Low Power Wide Area Networks (LPWANs) and satellite tracking, the location of tagged inventory can even be tracked during transit.

3. Better communication with customers

The vast amount of data being collected using the IoT provides companies with the opportunity to give valuable information to their customers. In retail, for example, it enables them to offer omnichannel personalised marketing. Personalised marketing has proved very successful for online companies who use data from their websites to provide tailored offers to individuals. However, for businesses with both online and bricks and mortar stores, the IoT enables data from all forms of interaction to be collected. Supermarkets, for example, can learn about a customerâ€™s in-store habits from their loyalty cards and send them online offers tailored around this.

Other types of IoT device can also help companies send valuable communications. Smart meters, for example, can help energy companies show customers where money is being wasted or where they can save from a different energy package.

4. The development of new services

Not only does IoT data help companies send valuable data to their customers, it can also create opportunities to offer them new services. The ability to monitor asset health, as mentioned above, means businesses can also track the health of the products they sell and offer their customers add-on maintenance services.

We get our boilers serviced annually as a precaution but wouldnâ€™t it be useful if the service company knew in advance that a part was about to fail and contacted us to replace it before it packed in? The same service could be applied to cars, televisions, computers, vacuum cleaners and many other items we use.

It is not just with breakdowns where additional services could be offered. Manufacturers of products which use consumable parts could monitor when those parts were due for replacement and offer a service to send them before they ran out. This would be ideal for replacing ink cartridges, lightbulbs and batteries, etc.

5. Improved security

Todayâ€™s IoT-enabled CCTV cameras bring many security advantages. Any business owner can now view multiple premises, internally and externally, from anywhere. And the advancement in CCTV technology means these systems use AI to identify suspicious activity, send out warning notifications and use facial and other visual recognition signals to track and record perpetrators.

6. Visual analytics

The same IoT technology is also helping businesses to gain greater insight into customer and employee behaviour. Connected cameras using artificial intelligence can gather valuable data which enables retailers to better understand how their customers interact with their store layouts, promotional materials and product displays. With employees, it is possible to learn how individuals interact with machinery, use their time and undertake processes. This can help improve workflows and lead to greater efficiencies on the shop floor.

7. Efficiencies and improvements

IoT data can help businesses make major efficiencies and develop improvements. It helps manufacturers speed up workflow and cut bottlenecks. It enables logistics companies to reduce energy costs, reroute vehicles when there are traffic jams or organise deliveries for the quickest routes. It even helps theme parks know which attractions are most popular and when: ensuring adequate numbers of staff are available and that unpopular attractions are replaced.

Conclusion

The data gathered from IoT devices is enabling companies to make important changes to the way they operate. It can improve asset and inventory management, enable better communication with customers and offer the potential for new services. It can also improve security, offer insights into customer and employer behaviour and help introduce efficiencies and improvements.

Welcoming the Fourth Industrial Revolution

How is IoT in Manufacturing Changing the Sector’s Landscape?

1. Inventory management

2. Predictive maintenance of assets

3. Field Service

4. Workforce management

5. Quality assurance

6. Cognitive operations and processes

7. Optimization and smarter resources

The Barriers to IoT Adoption in Manufacturing Sector

Interoperability of data

Lack of IoT Skillsets

Instances of data breach

Initiate Your IoT in Manufacturing Journey With Us

Statistics Proving the Uprising Market for Internet of Things (IoT)

A Brief Introduction of What is Internet of Things

Working of IoT Technology

4 Major Components of IoT Ecosystem

1. Sensors/ Devices

2. Connectivity

3. Data Processing

4. User Interface

What IoT Means to the Business World

1. Healthcare

2. Education

3. Retail

4. Sharing Economy

5. Real Estate

6. Travel

What is IoT?

Inventory management

Customer experience

Productivity

Remote work and operations

Data-driven insights

Conclusion

1. Asset tracking

2. Inventory Tracking

3. Better communication with customers

4. The development of new services

5. Improved security

6. Visual analytics

7. Efficiencies and improvements

Conclusion

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