Internet of Things
THE BENEFITS OF INTEROPERABILITY IN MANUFACTURING
The number of connected IoT devices reached 18.8 billion globally in 2024 — a 13 per cent increase from the previous year. However, this number is still nowhere near its peak. In fact, projections estimate that this number will grow to 40 billion by 2030. In manufacturing, connectivity between devices is no longer a luxury but a necessity. Here Beth Ragdale, software business manager at automation and control specialist, Beckhoff, explores how plant managers can ensure that their entire operation speaks the same language.
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nteroperability remains one of the biggest hurdles in industrial automation. Many industrial environments feature a mix of old and new technologies, each with its own communication protocols and proprietary software. This fragmentation results in inefficiencies, increased downtime and limited real-time decision-making capabilities. Overcoming these challenges could have a huge benefit for manufacturers. When machines, sensors and control systems can communicate effectively, production processes become more streamlined. Data can be shared instantly across the factory floor, allowing for real-time monitoring and optimisation.
One of the primary benefits of interoperability is the ability to predict and prevent equipment failures. By enabling different systems to share
performance data, predictive maintenance can be implemented. This minimises unplanned downtime, extends the lifespan of machinery and lowers maintenance costs.
Interoperability also allows manufacturers to adapt quickly to changing market demands, whether that means increasing production, modifying workflows, or integrating new technologies. A fully interoperable system ensures that new machines and software solutions can be easily added to the existing infrastructure without major disruptions or costly overhauls.
In a connected industrial environment, data from various sources, including IoT devices, production lines, and enterprise resource planning (ERP) systems, can be aggregated and analysed immediately. This provides plant
managers with valuable insights into process inefficiencies, energy consumption and quality control for example, enabling more informed decision-making.
Interoperability does not just benefit operations — it also enhances security and regulatory compliance. Standardised communication protocols help ensure data integrity and reduce vulnerabilities. As cybersecurity threats continue to evolve, having a unified approach to data management is crucial for protecting sensitive industrial information.
OVERCOMING OBSTACLES Despite its many advantages, achieving full interoperability is not without obstacles. Firstly, many older machines were not designed for modern connectivity standards, making integration
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May 2025 Instrumentation Monthly
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