IoT Can Change Manufacturing in Exciting Ways

The Internet of Things, or IoT, is a term that describes the collective body of ordinary technological devices that connect to computers wirelessly. These devices help humans work more efficiently by sensing, monitoring and keeping track of various processes. IoT devices help solve problems for companies that need very specific data to improve their manufacturing processes.

Although many firms embrace IoT devices to help run warehouses and supply management, adoption of this technology lags behind in the actual process of making an end product. The future of manufacturing is very bright, and companies that invest in connected sensors, IoT-ready machines and computer software to analyze the data stand to benefit the most versus competitors. Maintenance becomes easier, manual processes are more efficient, and these wireless devices save time, labor and money.

The benefits of IoT for manufacturers are well documented, but just 35 percent of U.S. manufacturers use connected sensors — mostly because the cost has yet to come down. Many of these early adopters put wireless sensors on older machinery rather than invest in new equipment. Some IoT devices require certain types of machines to connect to a wireless system, and that extra up-front money seems expensive. The key potential for savings comes from predicting when a line must come down for maintenance or due to a manufacturing glitch. Down time costs manufacturers profits, revenue and time.

However, preventing downtime is not the only benefit manufacturers reap from investing in IoT solutions. Costs of IoT devices and systems are starting to come down thanks to the initial adopters in big manufacturing firms. Smaller businesses can afford this technology eventually, and it's only a matter of time before smaller firms catch up to the big boys.

Sensors can detect emissions from plants, inefficient machines, energy-wasting processes and ways to improve a plant's energy consumption. Sensors can also detect wasted materials and the tolerable thresholds of components. As environmental regulations tighten, wireless sensors can bring manufacturers into compliance.

Companies must learn to interpret all of the information they receive from IoT devices. Copious amounts of data are great to have, but plant managers, supervisors and floor workers need to analyze what they see. That means the right software must accompany the sensors, monitors and control points. Much like sensors, software prices continue to drop.

Wireless devices can improve product quality using sensors coupled with small cameras and telemetry. Once components start communicating with each other, devices can alter a manufacturing process at the start of the line to make better products at the end of the process. This makes the job of quality control departments easier because quality assurance can occur in real time as products come down the line instead of after items make it to the QA stack.

All of these ways to improve the future of manufacturing have the right infrastructure in place. Companies should note a few concerns for IoT and manufacturing. Firms should have the correct security protocols in place to prevent data breaches. Cloud computing is a great way to share information collected from devices, but companies must protect their information. Manufacturers must balance real-time data analysis versus security.

IoT devices stand to reshape manufacturing for decades to come. The sooner companies adopt IoT strategies, the sooner they compete in a revitalized global economy.

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