Data acquisition
cent reduction in maintenance costs and a 35 per cent decrease in unplanned downtime based on their latest Digital Twins research.
QUALITY CONTROL AND IMPROVEMENT Maintaining high product quality is essential for any manufacturer. IIoT provides tools to enhance quality control by integrating real-time monitoring systems with either with MOM/MES and Enterprise Resource Planning (ERP) systems. This integration helps track production quality at every stage, identifying defects early in the process and reducing reject rates. For instance, a medical device manufacturer reduced its reject rates from 30 per cent to two per cent by implementing a real-time monitoring system integrated with their ERP system, as noted by Gartner in their recent report, Strategic Insights Leveraging IIOT & Connected Applications in Manufacturing.
SUPPLY CHAIN OPTIMISATION IIoT extends beyond the shop floor to the entire supply chain, providing end-to-end visibility. This visibility helps in tracking raw materials, work-in-progress, and finished goods in real time, reducing the need for buffer stock and improving order fulfillment accuracy. Combining IIoT with technologies like blockchain can further enhance supply chain transparency. According to Gartner, this ensures product authenticity and reduces the risk of counterfeiting. For example, a global pharmaceutical company used IIoT to track the movement of raw materials and finished products throughout its supply chain. Gartner reports that by integrating blockchain technology, they ensured the authenticity of their products and reduced the risk of counterfeiting, thereby increasing customer trust and regulatory compliance.
DRIVING EFFICIENCY GAINS WITH MANUFACTURING
Operations Management (MOM) and Manufacturing Execution Systems (MES) Manufacturing Operations Management (MOM) and Manufacturing Execution Systems (MES) are pivotal in driving efficiency gains in modern manufacturing. MOM encompasses all activities related to managing manufacturing
operations, while MES specifically focuses on the execution and real-time monitoring of production processes.
Manufacturing Execution Systems (MES) focuses on the execution of manufacturing processes on the shop floor. MES provides real- time visibility into production activities, helping manufacturers track work-in-progress, monitor equipment status, and ensure compliance with production schedules. By capturing real- time data on production performance, MES enables manufacturers to identify and address bottlenecks, optimise production schedules, and improve product quality.
Manufacturing Operations Management (MOM) provides a comprehensive approach to managing all aspects of manufacturing operations. MOM encompasses MES functions but also is extended to control quality control, maintenance, and inventory management ensuring seamless communication and coordination across all areas of the manufacturing process.
For example, a leading metal forming company integrated MES into their existing MOM system to enhance shop floor operations. DELMIAWorks reports that the MES solution provided real-time monitoring of machine performance, allowing the company to track production cycles, identify deviations from standard operating parameters, and take corrective actions promptly, resulting in a 20 per cent increase in throughput, and a 15 per cent reduction in scrap rates.
The integration of MES and MOM systems also facilitates predictive maintenance. By continuously monitoring equipment conditions and performance, manufacturers can predict when maintenance is needed and schedule it accordingly, minimising unplanned downtime and extending equipment life.
OVERCOMING CHALLENGES IN IIOT IMPLEMENTATION
Implementing IIoT systems comes with challenges, such as integration with existing infrastructure, data management, and cybersecurity concerns. Manufacturers should adopt scalable IIoT platforms that support diverse protocols and standards. Edge
computing can help manage and analyse data locally, reducing latency and bandwidth usage. Ensuring robust cybersecurity measures and technologies, such as strong authentication and encryption, is critical to protect sensitive data. Gartner highlights these considerations in their report on the benefits of IIoT for small to midsize manufacturers.
A successful implementation strategy involves starting small with pilot projects and scaling up as the organisation gains more experience and confidence. Gartner suggests it’s also essential to ensure that all stakeholders are on board and understand the benefits and challenges of IIoT.
FUTURE TRENDS: ARTIFICIAL INTELLIGENCE AND DIGITAL TWINS The future of IIoT in manufacturing will be shaped by advancements in artificial intelligence (AI) and digital twins. Digital twins, which are digital replicas of physical assets, enable real- time monitoring, simulation, and optimisation of manufacturing processes. Integrating AI with IIoT systems will provide deeper insights and predictive capabilities, further enhancing efficiency and productivity. According to Gartner, the market for simulation digital twins is expected to reach $379 billion by 2034, highlighting their growing importance in the industrial sector.
The integration of IIoT and connected applications is revolutionising the manufacturing industry. By leveraging real-time data, predictive analytics, and advanced automation, manufacturers can optimise their operations, improve product quality, and enhance supply chain visibility. As the industry continues to evolve, those who embrace IIoT will be well positioned to lead in the era of smart manufacturing, driving innovation and excellence in their operations.
The future of manufacturing is connected, intelligent, and remarkably efficient. Embracing IIoT is not just a technological advancement; it is a strategic imperative for achieving long-term competitiveness and success.
DELMIA
www.3ds.com/products/delmia
Instrumentation Monthly March 2025
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