This post was updated to reflect current trends and information.
Many countries and big businesses are active participants in the Fourth Industrial Revolution. Commercial associations and non-profit organizations were created to support the development of Industry 4.0.
Experts identify some basic technologies that include Industry 4.0
– Industrial Internet of Things
When manufacturing equipment is combined into one common network and is controlled by a single production management system.
– Augmented reality
Applicable for various purposes, for example, displaying instructions for repair and maintenance of equipment, etc.
– BIG DATA and business intelligence
Analytics of a large amount of data, which allows to optimize product quality, save energy and increase equipment uptime.
Today let’s talk about the most important technology in Industry 4.0 – Industrial Internet of Things
What is The Industrial Internet of Things (IIoT)?
The Industrial Internet of Things (IIoT) refers to the integration of internet-connected devices and sensors with industrial processes and systems. It extends the concept of the Internet of Things (IoT) to industries, such as manufacturing, energy, transportation, and agriculture, to enhance operational efficiency, productivity, and safety.
IIoT leverages various technologies, including sensors, actuators, cloud computing, machine learning, and data analytics, to enable real-time monitoring, control, and automation of industrial operations. It involves connecting physical devices, machines, and equipment to the internet, allowing them to collect and exchange data.
The key components of IIoT are:
Devices and Sensors: Industrial equipment, machines, and devices are equipped with sensors to collect data on parameters like temperature, pressure, humidity, vibration, and more.
Connectivity: IIoT relies on robust and secure network connectivity, such as Wi-Fi, Ethernet, cellular networks, or dedicated industrial protocols like MQTT or OPC-UA, to transmit data between devices, sensors, and backend systems.
Cloud Computing: IIoT systems utilize cloud platforms to store, process, and analyze the massive amounts of data generated by connected devices. Cloud-based services provide scalable and flexible infrastructure for data storage and computing resources.
Data Analytics and Machine Learning: IIoT leverages advanced analytics and machine learning algorithms to extract valuable insights from the collected data. These technologies enable predictive maintenance, anomaly detection, optimization, and decision-making.
Industrial Applications: IIoT finds applications across various industries, including manufacturing, where it enables remote monitoring of production lines, predictive maintenance of machinery, and optimization of supply chains. It is also used in energy grids for smart metering and grid management, in transportation for fleet management and logistics, and in agriculture for precision farming, among other sectors.
IIoT: History and Forecast
One of the first sectors where the Internet of things began to be actively introduced was the energy industry. Intelligent analytics is especially necessary where industrial facilities operate autonomously, distributed across different territories and vulnerable to various external threats.
The IIoT allows connecting natural gas-powered electricity plants located in different cities (for example, there are 1,793 natural gas-powered electricity plants in the United States) to a single forecasting and remote monitoring system, building digital models of the power station.
According to a report “IIoT & Remote O&M” published by the McIlvaine Company, the power industry represents a $ 19 billion annual Industrial Internet of Things (IIoT) market growing at 8 percent annually.
As reported by Machina Research and Nokia, revenues of the global market for the industrial Internet of Things will reach 484 billion euros in 2025, and the main industries will be Transport, Industry, Housing and Utilities, Healthcare, and Smart home applications. At the same time, the main revenue will come from applications, analytics, and services for end-users.
How does the Industrial Internet of Things work?
At the first stage of IIoT implementation, sensors, actuators, and other controllers are installed on industrial equipment. Thus, it becomes possible to collect information that allows management to obtain objective and accurate data on the state of production. Processed data is provided to all departments of the enterprise. This helps to establish interaction between employees of different departments and make informed decisions.
The information obtained can be used to avoid unplanned downtime, equipment breakdowns, reduce unscheduled maintenance and supply chain management problems, thereby allowing the company to function more efficiently.
Filtering and adequate interpretation of huge array unstructured data coming from equipment’s sensors becomes a priority for Industry4.0. Thus, for delivery information in understandable and clear form manufacture 4.0 use advanced analytical platforms. These platforms designed to collect, store and analyze data on technological processes in real-time.
Wireless devices such as smartphones, tablets, and sensors, are already actively used in manufacturing. Existing wired sensor networks expanding and supplementing by wireless networks, which significantly expand the use of monitoring and control systems at manufacturing enterprises.
As digital ecosystems evolve, manufacturing enterprises from isolated systems that perform all the necessary production processes on their own will be transformed into open systems uniting various production participants (Raw material suppliers, manufacturers, warehouses, distribution networks, etc.)
The Best Solution for Industry 4.0
A survey conducted by Honeywell with KRC Research among more than 200 executives in North American manufacturing companies revealed that unplanned downtime was seen as a major threat to revenue growth.
At the same time, 42% of respondents admitted that they operate equipment with a greater load than they should.
To avoid downtime at the enterprise, it is necessary to introduce technologies to detect and predict risks. Continuous monitoring of key indicators makes it possible to identify the problem and take the necessary measures to solve it. The instant analysis helps operators find the causes of problems faster.
Thus, manufacturers are approaching the point where they need to improve business results and make proactive, informed, more intelligent decisions without the need to change existing systems or infrastructure.
We have a solution for Manufacturers of all Sizes. FactoryEye is a great solution, designed for manufacturers.
With this comprehensive solution, manufacturers can track not only production but also all business process in real-time. It allows you to make dynamic, proactive decisions, delivering tangible business results at every stage.
Benefits of Switching to the Internet of Things Model
Using more and more robots and introducing IIoT in production will reduce staff costs, overhead and improve quality. For example, the Philips razor factory in the Netherlands operates in a dark manufactory with 128 robots. The entire plant staff consists of nine employees.
Lights-out manufacturing, often called a dark factory, is the methodology of production, and not a specific process. Factories that turn off the lights are fully automated and do not require a human presence on site.
Our solution Factory Eye gives to manufacturers a lot of benefits:
- Increased productivity
- Reduced material waste
- Improved on-time delivery
- Increased costing accuracy
- Better knowledge preservation
- Better control
Where to start IIoT?
The Industrial Internet of Things is changing business models, enabling companies to achieve high economic results. In the modern world, business success is determined by the ability to apply innovation and focus on results.
If you want to know more about what benefits the implementation of the principles of Industry 4.0 can bring to your business and how to transform it based on advanced technologies, contact us.