Welcome to the future. The internet is not just a click away; it’s now a part of every activity, and IoT has become a mainstay in industrial manufacturing. Industrial Internet of Things solutions have become indispensable for many manufacturers, and enhancing IIoT Security has become a priority for many businesses.
Regardless of your business approach to manufacturing, IoT is here to stay, and understanding the role of IoT in manufacturing amongst its other essential details is vital for successful implementation of IIoT in your industry. But first, what is IoT in manufacturing?
What is IoT in Manufacturing?
IoT in the manufacturing industry is also known as the Industrial Internet of Things. IoT generally refers to the interconnectivity of devices through networks and technology, allowing these devices to share information with the cloud and communicate with each other effectively. In manufacturing, it covers the connectivity of sensors, machines, instruments and other devices with computer systems and the cloud to improve manufacturing and industrial processes.
While IIoT sounds like a buzzword that refers to modern connections, sensors and uses, its history is surprisingly almost 6 decades old. In 1968, engineer Richard E Morley made an important breakthrough that would, in time, drive IoT in the manufacturing process to where it is now. He, alongside some friends, invented the programmable logic controller (PLC), which was adopted by General Motors and became indispensable in their automatic transmission manufacturing division. From there, IIoT’s evolution has included the standardization of the Ethernet, connectivity of PLC and more.
With the growth of IIoT, there has been an increased focus on industrial cybersecurity and safeguarding device interconnectivity. As we will see subsequently, this is one challenge in IoT adoption.There are notable IoT in Manufacturing examples, especially with named brands, including General Electric, which uses IoT in its jet engine manufacturing process, BMW in its vehicle production process and Phillips in improving the quality of its products.
The Importance of IoT in Manufacturing
IoT in the manufacturing industry is very important. With the improvement in technology and upgrades of older technology, IoT helps to improve the efficiency of the production process and product quality. It does more than that, and here are five applications of IoT in the manufacturing industry, highlighting its importance to manufacturers and brands globally.
Automated production lines
The integration of IoT sensors and robotics can help coordinate automated production lines. Instructions can be given remotely while parameters are adjusted automatically, improving the output and letting the production process run automatically.
Predictive maintenance
While it’s still advisable to call in a maintenance team to go through each device and machinery for defects and maintenance, IIoT makes the process much easier. Since IIoT devices share information and communicate seamlessly, operational failures and potential disasters are detected quickly, allowing employees to take preventative measures or take remedial actions. This helps the maintenance team to focus on what needs fixing, maintaining and just general check-in.
As mentioned earlier, your preference and needs can determine what option you choose. If you run an operation where unnecessary disruptions from false alarms can negatively impact your bottom line and your IT team is quite responsive to logs and notifications, then an IDS would be suitable for your company. But if your team has its hands full and you need an automatic security filter, then an IPS is a great option.
Facility management
Similar to predictive maintenance, IIoT is important for managing manufacturing facilities. With interconnected sensors and systems, factors such as humidity, air pressure, temperature and vibrations can be better monitored. This can determine proper facility conditions, and deviations that could negatively impact production can be noticed and handled effectively.
Asset management
With IIoT, manufacturers can easily access and monitor data on their assets in real-time. They can monitor their assets’ location and condition through the various phases of use and storage. This allows manufacturers to better manage their equipment, detect defects and perform timely maintenance.
Worker safety
Wearable devices like watches and helmets and their interconnectivity with other systems in the working environment make it easy to track workers’ health metrics. Metrics such as blood pressure, temperature, and more can be tracked, and alerts can be sent in case of toxicity or any trackable dangers within the work environment.
Overcoming Challenges in IoT Adoption for Manufacturers
Recognizing how important IIoT is and how it can benefit manufacturers and the industry at large, certain challenges slow down its mass adoption. We’ll examine these challenges and possible solutions.
- Security
The integration between equipment and systems within the manufacturing industry exposes various systems to cyber attacks. Hackers have been a real threat to IIoT, especially with its rise in adoption, causing damage to systems and disrupting supply chains.
A way forward in combating this challenge is to invest in ICS security and other cybersecurity measures. ICS security protects both software and hardware, ensuring security through the various manufacturing processes. Tools such as an intrusion detection system (IDS) make it easier to monitor the inflow and outflow of data, helping systems spot anomalies and respond with urgency. - Initial investment cost
Many modern tools are expensive, and including IIoT in the day-to-day running of factories, warehouses and industries can run up costs for logistics, workforce and the tools/systems too. There are ways to reduce costs, including gradually inculcating IoT solutions into manufacturing processes and addressing essential needs before other necessities. - Data Privacy
The Internet of Things involves connecting to the Internet, which opens up devices to infiltration, data compromise and data theft. The use of IIoT security tools is essential for preventing and containing data breaches. Manufacturers should invest in industrial cybersecurity tools, especially intrusion prevention systems (IPS), which monitor and prevent intrusion. - Lack of skilled personnel
With new technology comes new skills to learn. The coordination of data and its analytics might seem like an easy task, but scaling it through factories and storehouses requires professional hands. This is just one new area that comes with IIoT.
The solution here includes either hiring new talents to work on complex systems or training existing staff to manage the new systems better. - Compatibility between legacy equipment and modern IoT solutions
One challenge with new and legacy systems is how well they work together. IIOT often involves a bit of the new working with a lot of the old, and issues such as file formats, data access, controls and more can arise at various stages.
A solution to this challenge is to identify what solutions work well with each other and which do not and find other tools that can act as connectors or plugins to bridge the gap between legacy and newer systems.
Best Practices in loT for Manufacturing
To properly harness all that IoT has in manufacturing, there are some best practices to keep in mind.
Set clear goals
While IoT has many uses in manufacturing, harnessing its benefits is purely reliant on how well a manufacturer knows what they want and need. IoT is not a magic wand to fix all industrial problems, but setting the right goal can help set the tone for maximizing IoT for manufacturers.
Selecting appropriate IoT platforms
One way to address the challenge of compatibility is to secure the right IoT platform from the beginning. Picking a platform or products that work seamlessly delivers the necessary features for improving overall output and safeguarding data is necessary.
Adopt a phased implementation approach
Rather than overhauling existing systems or automatically adding sensors to every device and tool, adopting a gradual implementation strategy can help manufacturers get the best out of IoT. It also reduces the risk in situations where the technology being adopted fails.
Put maintenance structures in place
Network stability and reliability are important for the continuous, effective functioning of IoT systems. To enjoy peak performance, there should be scheduled maintenance for IoT systems and whatever supporting tools alongside existing factory equipment they work with.
Integrating IoT with Smart Manufacturing
Smart manufacturing involves linking physical assets such as machines, tools and sensors with their digital alter egos. IoT takes this link a step further, drastically improving communication between the physical and digital assets while increasing efficiency and reducing waste in the manufacturing process.
Improving smart manufacturing security through cybersecurity measures and physical safety standards improves the longevity and efficiency of these systems.The integration of IoT and smart manufacturing offers benefits like mass customization and agile manufacturing, more data-driven decisions, and real-time monitoring and information gathering, all of which contribute to better business operations for manufacturers. The role of IoT in manufacturing will constantly increase as time goes and its integration with smart security systems will only deepen. The question of whether manufacturers will harness this new normal will only be answered with time.
