IIoT and Smart Manufacturing: Your Guide to the Connected Factory
Today’s connected factories – those where smart manufacturing systems can communicate seamlessly using Industrial Internet of Things (IIoT)-enabled technologies – are the modern solution for manufacturers who seek to increase efficiency, boost repeatability and reduce operational costs. This beginner’s guide will explain IIoT, how the technology enables smart manufacturing facilities and the benefits this connected, informed approach brings to the plant floor.
What is IIoT in Manufacturing?
The Industrial Internet of Things relies on sensors, software and network connectivity to gather and share data from production processes and industrial equipment, such as robots, motors and pneumatic systems, to enable real-time monitoring, analysis and optimization.
Key Components of an IIoT System
Sensors & Actuators: IIoT-enabled sensors and actuators serve as the “eyes and hands” of the system. In IIoT-equipped systems, sensors gather machine and process data, such as temperature, pressure and position, and, based on that data, actuators perform actions, such as opening a valve or adjusting a motor.
Connectivity: The network, which may be wired or wireless, allows devices and systems to communicate.
Data Platform: An on-premise or cloud-based system collects, stores and processes equipment and process data gathered by IIoT-enabled sensors.
Analytics & AI: Analytics software and Artificial Intelligence technology serve as the “brains” in smart manufacturing systems. They analyze collected data to find patterns, predict failures and inform decisions.
How is IIoT Different from IoT?
The Internet of Things (IoT) is typically consumer focused and is used to control household devices such as smart lighting and smart thermostats. The IIoT is built for the factory floor, so IIoT technologies are designed for high reliability, security and integration with complex industrial machinery and equipment.
What’s the Difference between IIoT and SCADA
SCADA, or Supervisory Control and Data Acquisition, systems are built for – and excel at – real-time monitoring and immediate control of industrial equipment, but are often closed, on-premise systems.
IIoT enhances and expands upon SCADA systems. IIoT is more open, scalable and focused on gathering and analyzing large amounts of complex data from all systems, not just one process, to provide deep analysis, predictive insights and enterprise-level integration that can help decision makers optimize operations.
The Key Benefits of Smart Manufacturing
Implementing IIoT technology delivers tangible returns by providing real-time data and control. The primary benefits include:
Improved Product Quality and Consistency
IIoT systems can monitor production for potential quality issues in real time. Sensors can detect flaws and connected robots can communicate information about product accuracy. This information can be used to make on-the-fly adjustments, preventing quality issues. This also frees employees from manual monitoring and allows for data-backed process improvements.
Reduced Downtime
The ability to predict equipment failure is one of the major benefits of smart manufacturing systems. Instead of reacting to breakdowns, IIoT-enabled devices can alert operators and technicians to potential equipment issues so they know when a machine needs repair well before failure. For example, an alert can be sent to your phone if your compressed air system’s motor shows signs of wear or a pick-and-place robot runs into a problem. This allows you to react faster and schedule maintenance, to minimize or eliminate unplanned downtime.
Optimized Operations
IIoT gives managers a real-time view of the entire plant. IIoT technologies can monitor environmental conditions like humidity that can harm products or equipment or to point out production inefficiencies. Collecting and analyzing this type of data allows management to make informed, data-backed decisions so repairs can be scheduled before failure and process adjustments can be made to prevent defects, boost throughput and optimize operations.
How to Implement Smart Manufacturing in Your Facility
While the technology sounds complex, introducing smart manufacturing systems to your facility is achievable, especially with the right partner. Implementation focuses on connecting your existing and new systems.
As your automation partner, JHFOSTER can help with:
Connecting your controls: We can design and build UL508A-certified control panels that serve as a hub for controlling your equipment.
Integrating robotics: We deploy collaborative robot solutions that not only automate tasks but are also equipped with IIoT connectivity to feed production data back into your system.
Monitoring core systems: We integrate sensors and monitoring on critical equipment, such as your compressed air systems, to enable predictive maintenance and energy-efficiency tracking.
Providing flexible solutions: We can help you integrate flexible and adaptable automation platforms, allowing you to connect CNC machines, robotics and safety solutions into one cohesive, smart system.
Start Your Smart Manufacturing Journey with JHFOSTER
From identifying system problems sooner to optimizing equipment usage, IIoT can unlock new levels of productivity and ROI for your facility. You don’t have to navigate this transformation alone. The automation specialists at JHFOSTER have the expertise to help you evaluate, design and integrate smart manufacturing solutions that are tailored to your specific needs.
Contact us today to speak with an automation specialist to turn your facility into a connected smart factory.
