As we all know, the COVID-19 pandemic led to business shutdowns. Now, as we approach a vibrant economic recovery, the resilience of manufacturers will be tested. Between increased consumer demand for electronics and a slow recovery of the workforce, factories need to be prepared to return effectively.
Among the resilient businesses that have weathered the COVID-19 pandemic, a common characteristic is a strong digital foundation. Conversely, businesses that do not support automation, artificial intelligence, and the Internet of Things (IIoT) struggle to serve their customers. Today, manufacturers have ensured business continuity and are moving towards Industry 4.0; the next step for factories is to improve efficiency through operational improvements.
As a core element of Industry 4.0 and modern manufacturing, connectivity is key to unlocking the factory of the future. The use of sensors, enhanced by IIoT connectivity, allows manufacturers to continuously monitor every element of the factory floor.
Sensors use a range of detection methods to provide real-time insights into the factory floor. When implemented properly, they can capture data from vibration, motion, sound, and various other environmental factors, automatically providing employees with actionable analytics. Without continuous sensor monitoring of the factory floor, factory managers could miss crucial insights for maintaining smooth operations.
At the end of the day, you can't utilize the data you have unless you have the right tools to capture it. Sensors provide this capability, enabling employees to use data for analysis and closed-loop control. By selecting the right sensor technology and combining it with local computing engines and connectivity solutions, premium brands can maximize the efficiency, safety, and accuracy of their next steps, regardless of their product category.
Data-driven optimization
Embedding sensors in the production line helps factory managers collect and manage machine data from any source on a large scale.
Sensors' ability to capture data in the form of video, images, temperature, and pressure offers opportunities to support a wide range of functions. Through IIoT connectivity, employees can directly view machine health status through their devices, gaining unparalleled insights into the current condition of the machines. Once the data is received and stored in the cloud, it can be used throughout the factory for process improvements and the development of innovative products.
Sensors provide insights that would otherwise be unknown. Traditional machines are out of sync with modern manufacturing operations. Deploying IIoT-connected sensors onto machines can provide essential insights, such as avoiding production disruptions, predicting upcoming maintenance, achieving comprehensive safety, and supporting smart factory decisions.
Transparency of machine health status
The sensors continuously provide predictive and prescriptive analytics—reporting the machine's current status and even predicting potential problems before scheduled maintenance. Upon startup, the sensors collect uninterrupted data, monitor the machine's operation, and alert staff when issues arise.
Sensors provide employees with actionable intelligence to identify and remedy problems, preventing catastrophic failures. For example, sensors can alert technicians to irregular machine vibrations in a smart factory, triggering parts replacement orders and preventing costly downtime.
Visibility is arguably the most critical factor in maintaining manufacturing operations. Sensors are another way for employees to ensure they are prepared for any future production disruptions. When equipped with connected tools, people and machines can work in harmony, confirming efficiency and effective customer service.
With the impending economic recovery, ensuring efficiency and meeting growing consumer demand are crucial for manufacturers. Integrating sensors to eliminate downtime will be key to optimizing performance.
Sensors help factories prioritize safety.
The manufacturing industry is undergoing a digital revolution, and Industry 4.0 is progressing smoothly. Automated equipment is ubiquitous in factory floors. Robots, collaborative robots, and heavy machinery are valuable to manufacturers, but not as important as employees. Sensors provide a safety barrier for employees using or working near these devices.
Safety should be a top priority in factory workshops, especially with the increasing use of automated equipment. Sensors can not only observe how machines work, but also examine the environment around them to identify potentially hazardous working conditions. For example, sensors can monitor the distance between workers and robots or other unassisted equipment and trigger emergency shutdowns if personnel are in danger.
Forward-thinking companies are also exploring the concept of "sensors in a box" to expand the benefits of IIoT. This innovative idea revolves around a set of sensors being shipped and added to turnkey equipment, either close to the work area or observing the entire system from a distance to ensure full compliance with factory and field acceptance tests. This not only improves operation, ergonomics, and safety but also eliminates the need for employees to travel to each supplier's site and reduces the responsibilities of all relevant stakeholders.
Industry 4.0 is driving the development of traditional manufacturing with the connectivity and computing power of the digital world. As intelligent automation improves product quality and productivity, its benefits are transformative. Sensors are the cornerstone of smart products, improved experiences, and a better world.
