What manufacturers need to know about the Industrial Internet of Things

Generally, IIoT means using sensors to collect actionable data. It does not have to involve the Internet. It can simply reside in the building. For example, temperature and vibration sensors may measure the performance of mechanical bearings, and when both are on the rise, you know that the bearing is faulty and it is time to replace the bearing. This data allows you to replace the bearing at your convenience instead of waiting for the bearing to burst during the production process. Taking full advantage of IIoT can increase production, improve quality, simplify training, and reduce waste, maintenance, and process changes.

IIoT is also used to turn "products into services". For example, a washing machine can be equipped with sensors to feed back data about product performance to the manufacturer, tell the owner when to clean the filter, or suggest the best time to arrange the best washing time with the lowest electricity cost. If consumers pay for this service, the OEM will now receive recurring revenue.

Manufacturers can also do the same in products sold to other companies. GE is now doing this with locomotives, and there are many other examples.

The basic structure starts with simple sensors that measure temperature, vibration, sound, pressure, etc., and transmit this information to a database in the cloud. People can then query the database to learn more about their business. For example, how does the performance of this machine compare to another machine? Or, why can compressor 2 only output 75 psi?

Then, you can add machine learning (AI), which will perform its own queries and find interesting relationships between data that you might not have thought of – when machines #2, #10, and #25 are all in the following locations, Compressor #2 Poor performance. For example, at the same time, or #8 machine produces poor quality when using materials provided by X company.

In addition, you can use "digital twins" (they are digital representations of individual machines) to help predict performance or maintenance. Almost half of preventive maintenance is wasted, but everyone does it because shutting down is more convenient than ensuring that it is running unexpectedly to shut down the machine and make sure it is working properly.

AI and digital twins can help you accurately predict when and what maintenance you need, so you can still schedule maintenance, but only perform the maintenance that is really needed. Why add grease to parts that already have a lot of grease?

IIoT can also be used to collect augmented reality data. For example, trainees can use Hololens glasses, which can cover directions about how to operate machines or how to wire airplanes.

The major companies that provide these services-Microsoft Azure, AWS (Amazon), PTC, etc.-have made these "service" stacks interoperable. This means you don't have to worry about connecting them all-it's already done. And you don't need a 5G connection-4G is enough.

The most important part of integration is to start with the ending.

What do you want to accomplish?

What business do you need to know?

What functions do you want to perform automatically?

Which parts of the business are performing poorly?

Start small and cheap-just one machine, one machine or one department. Then expand.

Before you start, you need to know:

Sensors are usually a weak link in network security, make sure they are behind a firewall. Know who owns the data. If all of this happens in the factory, then you will have the data, but if you are using the data or providing it to a supplier or customer, you need to discuss this issue in advance.

If you are in the design phase of a new product, make sure to design the IIoT (especially the sensor) from the beginning-it will be difficult to add it later.

When starting to implement IIoT, remember that frontline supervisors and machine operators can manipulate a lot of this data. Make sure these employees can use it and be trained-this will allow you to further delegate representatives and focus on more important parts of your business.