Data acquisition R
eal-time data collection and analysis are at the heart of IIoT. By continuously monitoring equipment and production processes, manufacturers can detect anomalies, predict equipment failures, and take corrective actions before issues escalate. In today’s dynamic manufacturing landscape, efficiency is the cornerstone of competitiveness. The Industrial Internet of Things (IIoT) and connected applications offer transformative solutions to streamline shop floor operations, enhance productivity, and achieve significant cost savings. By leveraging real-time data and advanced analytics, manufacturers can optimise processes and make informed decisions that drive operational excellence.
UNDERSTANDING IIOT IN MANUFACTURING
The Industrial Internet of Things (IIoT) involves connecting physical industrial assets - such as machinery and equipment- to the Internet, allowing for real-time data exchange and analytics. According to Gartner, this integration provides manufacturers with unprecedented visibility into their operations, enabling predictive maintenance, quality control, and enhanced operational efficiency specifically tailored to industrial environments.
REAL-TIME DATA: THE HEART OF IIOT Real-time data collection and analysis are at the heart of IIoT. By continuously monitoring equipment and production processes, manufacturers can detect anomalies, predict equipment failures, and take corrective actions before issues escalate. Gartner reports that real-time data insights can lead to significant improvements in visibility and control across shop floors, reducing downtime and extending machinery life.
For instance, a prominent automotive parts manufacturer implemented an IIoT-based predictive maintenance system. This system monitored critical parameters such as vibration, temperature, and pressure, enabling the company to predict and address potential failures before they occurred. According to
DRIVING EFFICIENCY GAINS: THE VALUE OF IIOT & CONNECTED APPLICATIONS
Gartner, they reduced unplanned downtime by 30 per cent and extended the operational life of their equipment by 15 per cent.
ENHANCING OPERATIONAL EFFICIENCY IIoT enables the automation of various manufacturing processes, reducing human error and increasing production speed and accuracy. By optimising resource use through the use of sustainability, IIoT helps manufacturers reduce waste and operational costs. Additionally, improved visibility across the supply chain enhances coordination and efficiency. According to Gartner, this ensures that production schedules are met and customer demands are fulfilled. A case in point is a consumer electronics manufacturer that integrated IIoT solutions to monitor and optimise its production line. Gartner noted that by analysing real-time data, the company was able to identify bottlenecks and streamline operations, resulting in a 20 per cent increase in production efficiency and a 10 per cent reduction in material waste according
to Gartner’s Hype Cycle for Advanced Technologies for Manufacturers, 2023.
PREDICTIVE MAINTENANCE AND ASSET MANAGEMENT
Traditional maintenance strategies, often based on fixed schedules, can lead to unnecessary downtime or unexpected failures. IIoT facilitates predictive maintenance by continuously monitoring equipment conditions and performance. Sensors detect anomalies such as unusual vibrations or temperature changes, indicating potential issues before they lead to failures. Gartner’s research highlights that this proactive approach not only prolongs machinery life but also reduces maintenance costs and unplanned downtime.
For example, a large-scale food processing company utilised IIoT sensors to monitor the condition of its refrigeration units. By analysing the data, Gartner reports they were able to predict failures and schedule maintenance activities more effectively, resulting in a 25 per
By Louis Columbus, senior industry marketing manager at DELMIA
48
March 2025 Instrumentation Monthly
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