IoT in Manufacturing: Towards a Smarter Future

Lean manufacturing, which introduced efficient assembly line production and specialized machinery tailored for specific tasks, began significant innovation in the manufacturing industry from the early 1900s to the 2000s.

The emphasis shifted to the “smart factory” in the 2000s, which utilized predictive maintenance to prevent failures and integrated connected devices and automation to improve equipment efficiency.

In the next 5–10 years, digital factories will operate autonomously, utilizing digital twins to achieve clever, risk-free optimization.

However, for this innovation to be implemented on a large scale, IoT in manufacturing must be cognisant of the trends, hazards, and best practices that are currently in flux. This article delineates the Internet of Things (IoT), examines manufacturing trends and IoT problem points, and provides best practices for implementation.

What is the IoT (Internet of Things)?

The Internet of Things (IoT) is a network of physical objects that exchange data online through sensors and software. These devices encompass various capabilities, from basic household items to advanced industrial tools.

IoT in Manufacturing

IoT is frequently implemented in the manufacturing sector through the implementation of industrial robots and apparatus on the factory floor. The demands on management teams are increasing as a result of the fact that advanced connected devices require frequent updates, which makes them more vulnerable to attacks.

The manufacturing industry has experienced substantial changes in the past century, as previously mentioned. The onset of the Internet of Things (IoT) signifies a critical phase of innovation.

Related:  The Future of Manufacturing: Harnessing the Power of Industrial IoT

Key Market & IoT Trends in Manufacturing

The following patterns emerge when we focus on the technological trends in the manufacturing market currently and in the future:

1. The process of digital transformation is gaining momentum as factories transition from being smart to becoming a virtual industrial metaverse, employing immersive technologies like augmented reality (AR) and virtual reality (VR) to a significant extent. Manufacturers are transitioning from merely having access to large amounts of data to actively exploring the advantages of big data through the application of artificial intelligence and machine learning.
2. Gartner predicts that by 2028, the number of intelligent robots in manufacturing will surpass the number of frontline personnel. The software within the device is expanding in size and complexity, as well as becoming more reliant on other components and incorporating machine learning algorithms. Nowadays, “things” necessitate more frequent upgrades.
3. Cybersecurity vulnerabilities: The manufacturing industry is highly susceptible to cyberattacks. Software vulnerabilities that have been taken advantage of are the second most common method of attack, accounting for around 24 percent of all cases. To effectively address and prevent these attacks, manufacturers need to implement software curation and software supply chain security policies.
4. Cloud-based manufacturing is becoming increasingly popular as manufacturers transition to using Software as a Service (SaaS), containerising their software for improved scalability, and strengthening their security strategies. Furthermore, they tend to favour cloud-agnostic software, minimising the risk of being tied to a specific vendor.
5. Computer vision systems and autonomous robotics produce vast quantities of multi-dimensional data, contributing to the concept of the intelligent edge. Gartner forecasts that by 2025, over half of the company’s data will be generated and analysed at the edge rather than in traditional data centres or the cloud.
6. Digital twin technologies are currently gaining popularity as effective tools for enabling virtual factories. A digital twin is a computer-generated representation of physical things or systems that allows for simulations, virtual prototypes, and testing. More than 70 percent of firms lack a digital twin strategy for IoT devices.

Problems in Manufacturing With IoT

Manufacturers face challenges in three crucial areas as they strive to keep up with the constantly evolving Internet of Things (IoT) environment as a result of developments in the industry.

1. The time it takes to bring a product to market is slow and expensive. Similar to popular applications, edge devices are progressing quickly, becoming more software-focused and intelligent. This move has resulted in an increased frequency of software upgrades, which brings about both operational difficulties and additional expenses. The process of updating devices, especially those that are hard to reach due to their physical placement or absence of external IP addresses, can be extremely burdensome and costly.
2. Potential security threats: As the frequency of updates rises, the vulnerability of these devices to potential security risks also grows. Effective management and surveillance of software on edge devices is of utmost importance, particularly in high-stakes settings such as production lines, cars, and aircraft. Failures of edge devices in critical environments might result in far more severe effects compared to a standard server fault.
3. Constraints and inefficiencies in operations: Companies commonly procure their devices from many providers, resulting in increased complexity in device management. To efficiently manage a wide range of devices, organisations require a thorough understanding of their entire collection. This entails comprehending the devices that have been upgraded and the specific software that is being used on each gadget. Digital twins provide comprehensive software representations that assist in resolving the security and operational requirements of devices. The absence of well-defined software inventories or a cohesive Software Bill of Materials (SBOM) hinders the effective management and security of software.

Companies must successfully manage these hurdles to ensure strong and secure operations throughout their network of edge devices. To tackle these difficulties effectively, it is advisable to opt for a universal platform to manage your IoT software releases. By 2025, around 75 percent of organizations are projected to transition from using multiple-point solutions to platforms to enhance the efficiency of application delivery. This is a significant increase from the 25 percent observed in 2023.

Manufacturing & IoT

The integration of IoT in the industrial sector has completely transformed the way operations are carried out, shifting from lean manufacturing to smart factories and, currently, to virtual factories. As these technologies progress, the management and security of fleet device software become more and more crucial.

Manufacturers need to proactively anticipate and adapt to emerging trends such as AI-powered products, digital twins, and cloud computing, while also addressing vulnerabilities in cybersecurity and improving operational efficiency. Manufacturers can optimise their processes, bolster security, and maintain competitiveness in the dynamic IoT market by implementing universal platforms for software management.