Industrial IoT has many applications in manufacturing including: 1. Connecting machinery to remotely manage factory units and identify key performance areas. 2. Using sensors to monitor equipment condition and trigger maintenance alerts to reduce downtime. 3. Real-time monitoring of production lines to eliminate waste and optimize costs. 4. Tracking inventory globally to improve supply chain visibility and reduce costs.

1. Industrial IoT Applications |
IoT Applications in Manufacturing
Dr. Prashant S Humnabad
AP – Dept. of ME, SIR MVIT, BENGALURU

2. Industrial IoT Applications
Industrial Internet of Things (IIoT) is an ever growing and rapidly increasing sector that
accounts for most of the share of IoT spending in the global market.
Industrialists & manufactures in almost every sector have a tremendous opportunity to
not only monitor. But also automate many of complex process involved in manufacturing.
For long time industries and plants have had sensors and systems to track progress but
IoT takes a step further and provides intricacies to even the minute problems.

4. a. Digital/Connected Factory
The machinery that is embedded with an IoT system can transfer information
related to operations to the people such as the original equipment manufacturers
and to field engineers.
This way process automation and optimization is made advantageous by enabling
operation managers and factory heads to remotely manage the factory units.
Along with this, a unit which is digitally connected helps in establishing a better line
of command and also helps to identify areas with key results and areas that might
have potential problems for managers.
b. Facility Management
The IoT sensors placed inside manufacturing equipment triggers alerts based on
condition-based maintenance. Most of the machine tools are critical and are designed
to function between a specific temperature and vibration ranges.
Whenever an equipment deviates from its prescribed parameters, IoT sensors can
actively monitor machines and send an alert. Manufacturers in this way can conserve
energy, reduce costs, eliminate machine downtime and increase operational
efficiency, by ensuring the prescribed working environment for machinery.

5. c. Production Flow Monitoring
IoT in manufacturing is capable of monitoring an entire production line be it from the
refining process completely down to the packaging of final products. Because this
complete monitoring of the process takes place in real-time.
It provides us the scope to recommend any adjustments in operations for better
management of the industry’s operational cost. Since the monitoring is done quite
closely, it lags in the actual production thereby eliminating wastes and unnecessary
work.
d. Inventory Management
This is best industrial IoT application, through IoT systems monitoring of events across a
supply chain is done.
These systems allow one to track the inventory and trace it globally on a line-item level.
This way the users are notified if there are any significant deviations from the plan of
action.
As a result, this provides a far-reaching and cross-channel visibility into inventories which
helps managers in getting realistic estimates of the available material, the work in
progress and the estimated arrival time of new materials.
Ultimately this makes supply more optimal and reduces additional and shared costs that
arise in the value chain.

6. e. Plant Safety and Security
A workers’ safety and security in the plant improve by IoT combined with big data
analysis. The IoT system monitors some Key Performance Indicators (KPIs) of health
and safety, such as the number of injuries, frequent rates of illness, vehicle
incidents, and property damage or any kind of loss incurred during daily
operations. Thus, an effective monitoring system ensures better and effective
safety. If there are some indicators that are lagging, they addressed, thus ensuring
better health, safety, and environment (HSE) issues. That’s no one can ignore
industrial IoT applications.

7. f. Quality Control
A product cycle has various stages, IoT sensors collect a mixture of product data and
other third-party synchronized data from the stages of a product cycle.
This data contains information on the composition of raw materials used in the
making of a product, the temperature & working environment, different wastes, the
importance of transportation etc.
On the final making of the products. Moreover, the IoT device can also provide data
about the customer sentiments while he/she uses the product.
All of these inputs from different sources and through IoT systems can analyze to
identify and correct potential quality issues.

8. g. Packaging Optimization
Manufacturers can gain insights into the
usage patterns and handling of product
from different customers by using IoT
sensors embedded in products and/or
packaging. There are smart tracking
mechanisms that can trace product
deterioration during the product transit.
Other factors such as weather impact, a
condition of roads and other environment
variables on the product. Through these
insights, one can re-engineer products and
their packaging for delivering better
performance in both costs of packaging and
customer experience.

9. h. Logistics and Supply Chain Optimization
In this industrial IoT applications, it provides access to real-time supply chain
information by tracking materials in transit, products, and equipment as they
move through the supply chain.
Through effective reporting manufacturers are able to collect and feed the
delivery information into systems like ERP, PLM etc.
If the plants get to connect to the suppliers, all the concerned parties in the
supply chain can trace interdependencies, manufacturing cycle times and
material flow.
As a result, this data will help manufacturers to reduce inventory, predict
potential issues and also reduces capital requirements.

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