IIoT: How the Industrial Internet of Things is Transforming Manufacturing

is a key element of the broader concept known as Industry 4.0 – the next phase of the industrial revolution, focused on automation, digitalization, and intelligent systems. As modern technology becomes increasingly integrated into our daily lives, the term “digitalization” is frequently on the lips of business owners who want to remain competitive. One of the most significant trends in this space is IIoT. But what does that mean in practice? It means connecting machines, devices, and sensors into one large network that allows for real-time monitoring and optimization of production processes.

Imagine your machines not only performing their tasks but also communicating with one another, gathering data, and responding when something goes wrong. This is precisely how IIoT functions, using sensors and intelligent systems that collect information about device performance, energy usage, and even temperature. All this data works to improve efficiency and reduce costs.

One of the most exciting applications of this technology is predictive maintenance. In traditional manufacturing, repairs are often made only after a machine breaks down, which can lead to downtime and losses. In the world of IIoT, machines signal the need for maintenance before a failure occurs. This enables companies to avoid unplanned downtime and costly repairs.

One of the biggest advantages of IIoT is real-time monitoring. Systems collect data continuously and deliver it to operators or production managers, who can respond immediately to any issues. Thanks to this technology, they have visibility over everything happening on the production floor, even when they aren’t physically present.

Moreover, IIoT facilitates greater automation. Machines can “make decisions” without human intervention, saving time, eliminating errors, and making production more efficient.

IIoT is especially valuable when implementing IT systems such as MES or traceability systems because it automates data flow from machines, even older ones. This is a cost-effective solution that allows IIoT devices to connect to IT systems without needing to interfere with the machine’s PLC (Programmable Logic Controller). It enhances efficiency without requiring expensive machinery upgrades.

In industrial settings, it’s often more about a localized IIoT network – a network of interconnected devices rather than a public network. These devices can be battery-powered, connected via wireless networks, and, importantly, many can be implemented non-invasively. A good example would be a temperature sensor attached to a device with a magnet.

The main benefit of IIoT is that you don’t have to overhaul your entire company infrastructure. This alleviates concerns for many business owners who previously thought their old and complex machine park would be too restrictive for digitalization.

Another significant advantage of IIoT is that devices can communicate with each other without needing a central control point. How does this work? A sensor can pass information directly to another sensor. This also helps reduce costs.

Think of it like the human body’s circulatory system, where the heart pumps blood through a network of veins and arteries to all organs. In a machine, the central control system usually connects all the sensors. IIoT, however, overturns this structure, eliminating the need for a central control point. Each sensor is an independent entity and can communicate with other sensors, like each organ having its own dedicated heart.

Self-diagnostics and the vast amounts of information that IIoT sensors can send are also crucial. Consider a simple temperature sensor, which usually just indicates temperature. In contrast, an IIoT sensor can provide additional information (e.g., diagnostics on how close the temperature is to the sensor’s limit, whether the sensor is low on power, if it’s providing unreliable measurements, or if it’s damaged).

It’s important to note that while IIoT offers numerous benefits, fully leveraging its potential requires a central data gathering point to allow for data segmentation (this helps differentiate between diagnostic messages and information related strictly to the technological process). Ideally, your system should have algorithms that process this information and present preliminary conclusions.

Automatic data analysis also needs to be tailored to different users. For instance, a technical specialist monitoring the technological process can assess whether a measurement is good or bad based on IIoT device readings.

For example, we know the optimal human body temperature is 36.6 degrees Celsius, and if it rises to 39, it indicates illness, as we have a simple indication. Things get more complex when dealing with vast data. This is why a manufacturing plant needs a system that analyzes information so that employees can focus on what to do to fix the issue rather than on laborious data analysis. This also shortens response times when a problem arises.

Imagine in a manufacturing plant, a machine indicates that, say, welding is happening at too low a gas pressure. Based on this information, you need to decide whether to change the gas cylinder or check the regulator. You spend considerable time on diagnostics, perhaps even needing to halt production. An automated analytical system relieves you of this task, enabling faster action.

The Industrial Internet of Things is not about the future—it’s here today! Many companies have already invested in IIoT, gaining a competitive edge and opening up new possibilities. Let’s face it – company data is currency, and time is money. Therefore, it’s worth considering implementing IIoT, which offers tools to revolutionize your factory. Is your company ready for this change?

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