Industrial IoT (IIoT) refers to integrating devices, machinery, & sensors into a network that connects to the Internet. The primary objective is to gather data and perform data analysis for ongoing process enhancement. Various IIoT applications are currently available, and this new paradigm has encouraged numerous companies to adopt it to enhance productivity, optimize expenses, and increase profits.
The IIoT market is continuously growing, with layers already implementing it. Although studies provide varying estimates of the market value of IIoT in the upcoming years, the most significant reports indicate that investment will enhance at least threefold.
It would be prudent to gain an understanding of the primary IIOT applications and also how to apply the system to gain a competitive advantage.
Applications of IIoT Manufacturing
According to studies released by Deloitte, the corporate world places significant importance on creating IoT environments. In their “Industry 4.0” report, 94 percent of survey participants indicated that Digitalization is a crucial strategic goal for their organization.
Although this trend is observed worldwide, in the industrial sector, companies should recognize the significance of IIoT applications in developing sustainable processes for the future.
· Automated & remote equipment management
One of the principal Industrial IoT ( Internet of Things ) applications is the automation of equipment management, which enables the centralized system to manage & monitor all processes of the company.
The capacity to manage equipment remotely through digital machines & software also means that it is feasible to control multiple plants situated in several geographical locations.
This endows companies with an unparalleled capability to observe the progress of their manufacturing in real-time, as well as the ability to analyze historical information related to their processes. Collecting and utilizing this data fosters an environment where informed decisions are prioritized and support the enhancement of processes.
· Predictive maintenance
Predictive maintenance involves identifying the requirement for machine maintenance before a crisis occurs, which could result in an urgent halting of production. Therefore, it is one of the reasons for implementing a system for data acquisition, management, and analysis.
Among the most compelling IoT applications is a system that works through sensors installed on machines & operating platforms. These sensors can send alerts when certain risk factors emerge. For instance, sensors that monitor machines or robots submit data to the platforms, which analyze the data received in real-time and apply advanced algorithms capable of issuing warnings when parameters such as high temperatures/vibrations exceed normal limits.
· Faster implementation of improvements
Industrial IoT provides valuable information to the individuals responsible for improving processes within a business model, such as process, quality, or manufacturing engineers. They can access data & analyze it more fastly and more efficiently, allowing them to make the necessary process adjustments remotely. This also speeds up the application of changes and improvements in operational intelligence & business intelligence, which offer competitive benefits to many businesses.
· Pinpoint inventories
Automated inventory monitoring is another important application of Industrial IoT( Internet of Things) systems. It ensures compliance with plans and alerts the relevant personnel in case of any deviations, helping to maintain a consistent & efficient workflow.
· Quality control
Another critical IIoT application is the capability to check the quality of products at every stage: from the raw materials used in the process to their transportation through innovative tracking applications to the response of the end client upon receiving the product.
The data collected through the monitoring of product quality at all stages is crucial for analyzing the efficiency of a company and making necessary improvements. This includes promptly detecting any issues in the production chain and optimizing processes. Moreover, in industries like pharmaceuticals or food, where risks must be minimized, this monitoring is particularly essential.
Industrial examples of IIoT Manufacturing
Many industrial giants have already embraced the Industrial Internet of Things and reported positive results. Let’s take a closer look at their expertise.
Caterpillar
In the 1990s, Caterpillar, a United States Fortune 100 company that produces heavy machinery, incorporated IIoT into its operations. It is one of the successful instances of IoT implementation in the United States. The company now has over 500,000 assets worldwide, making it the largest connected fleet in the industry.
The company implemented IIoT for predictive maintenance of machines & fleet monitoring & management, but it did not stop there. Caterpillar now produces products with built-in Industrial Internet of Things technology capabilities for its customers. For example, their excavators are considerably easy to operate than traditional ones.
Additionally, Caterpillar’s implementation of IIoT positively impacts its clients by improving equipment & machinery utilization. For example, via predictive maintenance, the company was able to save over $600,000 for one of its mining clients, while another client reported a 20% increase in productivity through the use of Caterpillar’s autonomous vehicles.
Shell
Shell, a major global oil & gas company based in the UK and the Netherlands, successfully implemented IoT( Internet of Things) sensors in a project in Nigeria, resulting in a cost savings of over one million US dollars through continuous monitoring of oil fields. That system was designed to track the state of some pipelines, including their temperature and pressure.
During the implementation process, Shell faced challenges related to the rugged terrain of the pipeline’s location, long-distance connectivity, and scalability. However, the final solutions successfully overcame these complications.
Komatsu
Komatsu, a mining machinery manufacturer based in Japan, has reported significant improvements in Industrial Internet of Things implementation. The company has developed its own IoT(Internet of Things) system, KOM-MICS, which collects data from sensors installed on tools & robots. Thanks to a continuous flow of information, the company was able to enhance the machine operation rate by 25%.
Subsequently, with the emergence of cloud computing, the company opted for Microsoft Azure to store the information collected from the machines. This facilitated the process of expanding and integrating more machinery from their branches worldwide into the KOM-MICS system.
