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The Smart Factory is Here: Top IIoT Abilities for the Modern Manufacturer

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rasika joshi

IIoT is now the largest concept in factory automation today and this technology already affect the way factories operate. Hence, it is important to interpret the ideas being utilized, rectify how IIoT technologies are already being executed in smart factories.

Smart Factory

Smart factories are an essential part of the IoT. At the same time, IIoT refers particularly to the affect of this innovation on industrial applications.

IIoT technologies together generatesmart” networks. Smart factory gives plant managers with remote access to wirelessly-connected machines — and access to a means of data on the operation of those machines — by automating the interaction between industrial automation equipment and systems. Smart sensors — containing those with wireless and IO-Link abilities -are an essential part of making the smart factory a reality.

Top Abilities of Smart Factories

Below are few abilities of smart factories that are remote monitoring, predictive maintenance as well as process optimization.

Remote Monitoring

Complete visibility into the operational status of machine components enables plant managers to remotely analyze and recognize systems instantly and identify and rectify issues before the effect on machine availability and productivity compounds.

The data recorded by various devices can also be utilized in OEE (Overall Equipment Effectiveness) calculations. Not only can operators acknowledge to alerts rapidly as they occur, but historical data can be utilized to track machine uptime, production volume, rejected parts as well as other key measures.

Predictive Maintenance

Predictive analytics enables for more precise planning of machine maintenance, which can assist to minimize machine downtime, improve mean time between failure (MTBF) as well as minimize costs of unneeded preventative maintenance and spare parts inventory.

With predictive maintenance, much of the assumption is eliminated because maintenance decisions can be created based on the historical and real-time data from the machine itself. For instance, wireless sensors that estimate vibration and temperature, current as well as pressure can recognize machine and system faults that tends to unplanned downtime and machine failure. The wireless sensors then share that data to a wireless controller that makes data accessible instantly (via text or email alerts) and for long term analysis.

By analyzing machine components in real-time, problems can be recognized and solved before they become too serious and cause additional damage or result in unplanned downtime. Over time, the historical data generates a valuable machine performance log that can be utilized to make more illuminated maintenance decisions down the line.

Process Optimization

The inter connectivity presented by IIoT technologies allows coherent communication among machines, components etc. This enables for data-driven process optimization — increasing efficiency and required on the line, minimizing the requirement for technicians and managers to continuously check each production line and for workers to quit their workstations when they require assistance.

A system like this could be place so that an operator drives a button or flips a switch to alert the manager or technician that he or she is required on the production line. A tower light connected to the gateway’s outputs would then specify which production line requires a manager’s attention, and colors could be allocated to specify the requirement for a technician (yellow) or manager (red).

By using a wireless network of connected devices to modernized communications, managers, technicians, and line workers are capable to utilize their time more effectively and productively. On the other hand, a wireless solution can be utilized in pick-to-light and call for parts applications.

Overall, the abilities presented by IIoT mean that these technologies are not only short-term investments or solutions to instant problems; rather, they allow constant improvement by giving companies with the capability to resolve new concerns as they arise — increasing the value of the investment over time.

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