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  • Dhruman Gohil

Impact of IoT in traditional Manufacturing Operations.

Updated: Jan 6

The integration of IoT (Internet of Things) into manufacturing enables manufacturing enterprises to fully digitalize their processes and operations. Real-time data is collected by sensors and other data sources and they are embedded into conventional machines and processes. The data is then uploaded to the cloud and the internet and made available to managers and other stakeholders via software data reports and insights. It is possible to track the work of each machine operator and manufacturing unit and provide suggestions to boost productivity. KPI (Key Performance Indicator) can be formed as per data to increase the agility, controlling process, forming and integrating strategies in the traditional process. In manufacturing organizations, IOT can be integrated in the following ways:

1. Quality Assurance and Control:

Sensors can be integrated into machines to identify flaws in the made product and immediately notify the manager so that the appropriate corrective action can be performed, such as altering raw material quantities, changing machine specifications, or identifying a machine operator error. Managers can help solve issues by setting up alerts and notifications when there is a drop in quality or some uncertainty in the created product. Real-time data insights can be used to estimate and improve the quality of operators and equipment based on the quality of the output.

2. Production planning and inventory management

IOT and real-time data insights assist managers in optimizing the planning process by helping them plan their production and strategies in accordance with orders, needs, demand forecasts, and predictive analysis. Real-time data analysis allows for the expansion of product life cycles, better scheduling and management of manufacturing, and simple supply chain tracking. Storage of raw materials and manufactured goods, as well as their segmentation according to orders and demand through affiliated companies, is a significant difficulty in manufacturing factories. Installed on products are RFID tags, and IOT allows for cloud-based tracking of those tags.

3. Supply Chain and logistics

In any supply chain, there are multiple stakeholders such as Suppliers, Manufacturers, Distributors, logistics providers, retailers, and consumers, so having complete transparency and visibility in the chain is a real challenge. Due to the IoT integration in the supply chain, every member of the chain gets real-time data insights of the process of other stakeholders. Logistics managers can track the stage of manufacturing and plan their operations. All other members also can track the logistics and their trucks/transportation through IoT Cloud.

4. Equipment maintenance

Sensors are integrated into the equipment, and machinery and all the data is collected and transferred to stakeholders in the form of reports. Sensors connected to the machinery and engine can detect real-time conditions like temperature, usage, energy, quality, pressure, life cycle, etc. Regular reports of equipment help to avoid excess repair costs after problems occur. Regular monitoring and equipment downtime can be tracked, noted, and stored which helps in planning and strategizing maintenance activity.

Read our 1st Blog - What is Industry 4.0?

Read our 2nd Blog - What is Supply Chain Management and its importance?

Read our 3rd Blog - What is Intelligent and Smart Manufacturing?

Read our 4th Blog - Industry 4.0 Technologies and their Applications - IoT, AI

Read our 5th Blog - Indian Industry 4.0 Challenges that affect the adoption

Read our 6th Blog - Applications of Real time Data in Manufacturing Operations

and remaining blogs.

Written by - Dhruman Gohil

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