Smart Factories

A smart factory uses IoT solutions to automate the monitoring and management of the machines and equipment used in the factory. The term Industrial IoT is often used when used in factories. The main difference between IoT solutions in factories and homes is that the sensors and controllers used in factory environments generally need to be more accurate and reliable since critical and expensive machinery is involved. They also need to be sturdy due to the environment, which is usually hotter, dustier, and subject to harsher activity than in a home.

Examples of Industrial IoT solutions include:

Operational Efficiency Many critical machines are designed to function within certain temperature and vibration ranges. Sensors can monitor machines and send an alert when the machine deviates from its rated operating parameters. By ensuring the prescribed working conditions for machines, manufacturers can conserve energy, reduce costs, eliminate machine downtime and increase operational efficiency.

The use of sensors in manufacturing equipment enables predictive maintenance. Sensors can detect if a part of a machine is likely to fail and the IoT solution can proactively schedule a maintenance service or order a replacement part. The solution can also connect with the production scheduling system, which will adjust the expected production volumes based on the expected downtime of the machine.

Accordingly, transport logistics can be rescheduled, and customers can be alerted regarding possible delays in their shipments. Such multiple remote and disparate IoT applications connecting, exchanging data, and working together, can provide huge value to a business.

Safety and Security IoT solutions can be combined with image processing and data analysis that further improve the overall worker safety and security in the plant. Proximity sensors can detect and alert if workers or visitors get too close to dangerous equipment. Sensors and image analysis solutions can detect if people are wearing the right personal protection equipment in hazardous areas.

Sensors can measure several work environment parameters to avoid prolonged exposure to harsh conditions such as harmful gases, excessive noise, heat, or humidity.

Wearable sensors can detect signs of fatigue, dehydration, or exhaustion encountered by their workers, thus encouraging them to take a recovery break as needed.

These are only some examples of how IoT solutions can create a Smart Factory, there are many more creative solutions that can be implemented.