2024: The Year of IoT in Manufacturing
Introduction
The Internet of Things (IoT) has been transforming manufacturing for years, but 2024 will likely be the year it becomes ubiquitous. By integrating sensors, software, and connectivity into production equipment and throughout facilities, manufacturers gain unprecedented visibility into operations. This enables optimization, predictive maintenance, quality control, and more.
As costs decline and capabilities improve, IoT adoption accelerates. By 2024, IoT will no longer be an initiative at leading manufacturers – it will be an integral part of operations. This article explores how IoT will transform manufacturing in the coming years.
Increased Operational Efficiency
One of the biggest impacts of IoT is improving efficiency. Sensors provide real-time data on production output, equipment performance, quality, inventory, and more. Software aggregate and analyze this data to optimize processes.
For example, combining sensor data with AI algorithms helps predict potential maintenance issues before they cause downtime. This predictive maintenance minimizes disruptions and reduces repair costs. Sensors also track cycle times, output rates, and other metrics to identify opportunities to improve throughput.
IoT enables overall equipment effectiveness (OEE) to be measured in real-time across the facility. Managers gain visibility into bottlenecks and can adjust workflows to improve OEE. By 2024, driving all production decisions through IoT data analytics will be standard practice.
Flexible Automation
IoT connectivity allows production equipment from different vendors to be integrated and synchronized. This facilitates flexible manufacturing where production lines can be reconfigured based on demand.
For example, a facility may switch a line from producing appliances to electric vehicles overnight. This requires connecting, coordinating, and calibrating all of the robots, CNC machines, conveyors, and other equipment on the line. IoT enables this rapid reconfiguration for faster changeovers.
Likewise, IoT allows production lines to adapt output in real-time. If a sensor detects defects rising on an automotive line, the system can slow the line speed to avoid quality issues. Combining machine learning with IoT data enables this autonomous optimization.
Predictive Quality Control
IoT gives manufacturers the data needed for next-generation quality control. Smart sensors can detect anomalies in components or finished products indicating defects. Issues can be flagged for rework before products leave the facility.
Vibrations or heating in motors can warn of potential failures before they slow production. Early warning allows parts replacement during planned maintenance rather than after breakdowns.
By combining IoT sensor data with artificial intelligence, manufacturers can move to predictive quality management. Instead of random inspections and testing on production lines, AI algorithms will automatically analyze sensor data to identify potential quality issues and take corrective action in real-time.
Data-Driven Design
IoT enables a digital thread connecting product design, manufacturing, and use. Sensor data from the factory floor and customer sites provides feedback to design engineers. This facilitates data-driven product development and continuous improvement.
For example, accelerometers on motors can indicate wear under various operating conditions. That data can be used to redesign components for greater longevity and reliability. Production line sensor data can highlight manufacturing challenges to improve part design for ease of assembly or quality control.
By 2024, this digital thread will be standard practice, enabling rapid design iteration and dramatically compressed product development cycles. IoT data will drive design, rather than just static design criteria and specifications.
Conclusion
The manufacturing sector will be virtually unrecognizable by 2024 as IoT becomes an integral part of all operations. Production efficiency, flexibility, quality control, and product design will all be optimized through intimately connected systems. Early adopters are already gaining major competitive advantages while laggards risk obsolescence. IoT is quickly becoming mandatory in manufacturing, and 2024 will be the year it becomes ubiquitous.
