SUPPLY CHAIN SOLUTIONS
DRIVING EFFICIENCY GAINS: THE VALUE OF IIOT AND CONNECTED APPLICATIONS
Senior industry marketing manager at DELMIA, Louis Columbus 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, The Industrial Internet of Things (IIoT) and connected applications offer transformative 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 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 improvements in visibility and control across 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 Gartner, they reduced unplanned downtime by 30 percent and extended the operational life of their equipment by 15 percent.
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 that production schedules are met and 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 and a 10 percent 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 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 percent reduction in maintenance costs and a 35 percent 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 MOM/MES and Enterprise Resource Planning
20 MARCH 2025 | FACTORY&HANDLINGSOLUTIONS
(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 percent to 2 percent by implementing a real- time monitoring system integrated with their ERP system, as noted by Gartner in their recent report, Strategic Insights Leveraging IIOT and Connected Applications in Manufacturing.
SUPPLY CHAIN OPTIMISATION entire supply chain, providing end-to-end visibility. This visibility helps in tracking raw goods in real time, reducing the need for 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 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) manufacturing. MOM encompasses all activities related to managing manufacturing operations, and real-time monitoring of production processes.
Manufacturing Execution Systems (MES) focuses on the execution of manufacturing 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
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