The essence of Industrial Internet of Things (IIoT), what is that? Imagine if every machine in a factory could talk to each other and share important information. It involves connecting all the equipment, sensors, and systems in an industrial setting to the internet, allowing them to exchange data in real-time.

This connectivity helps factories operate more efficiently by predicting when machines might break down, monitoring processes closely to avoid mistakes, and ensuring everything runs smoothly and safely. The Internet of Things (IoT) and automation technologies are revolutionising the manufacturing industry by enabling real-time data collection, advanced analytics, and automated processes. Here’s what we will cover in this article:

Table of Contents

1. Introduction to IoT and Automation in Manufacturing

• Overview of IoT and automation technologies

• Importance of OEE in manufacturing efficiency

2. Cons of automation and how to tackle them

• Job Displacement and Unemployment

• Initial Implementation Costs

• Technical Challenges and Limitations

• Reduced Human Interaction and Customer Experience

• Dependency on Technology and Loss of Human Skills

3. Advantages of Automation Technologies

• Streamlined production processes

• Reduction of human error

• Increased production speed and consistency

4. Implementing IoT and Automation for OEE Improvement

• Steps for integrating IoT and automation in manufacturing

• Best practices and considerations

• Case studies of successful implementations

5. Future Trends and Innovations

• Emerging technologies in IoT and automation

• The future of smart manufacturing

• How to stay ahead with continuous improvement and innovation

Introduction to Industrial IoT and Automation in Manufacturing

IoT refers to the network of physical devices embedded with sensors, software, and connectivity, allowing them to collect and exchange data. This interconnected ecosystem enables manufacturers to monitor equipment performance, track production processes, and optimise operations in real-time.

Automation technologies, on the other hand, involve the use of machines and software to perform tasks that were traditionally done manually. This includes robotic arms for assembly lines, automated guided vehicles (AGVs) for material handling, and computer numerical control (CNC) machines for precision manufacturing. When integrated with IoT, these automation systems can operate like a smart factory, more efficiently, respond to data insights, and adapt to changing conditions without human intervention.

GlobalReader's Solutions: GlobalReader offers a range of tools and services that harness the power of IoT and automation to improve manufacturing efficiency:

• Real-Time Factory Tracker: Our analytics tool provides continuous monitoring of production processes and equipment status. By leveraging IoT sensor, the software collects data on machine performance, production rates, and operational conditions, enabling manufacturers to identify issues and optimise processes immediately. 

• Predictive Maintenance: Using IoT sensors and advanced analytics, GlobalReader's predictive maintenance solution predicts equipment failures before they occur. This proactive approach reduces unplanned downtime and extends the lifespan of machinery, ensuring that production remains uninterrupted. 

Operator Performance Tracking: GlobalReader’s Operator tool monitors and analyses operator activities in real-time. This data helps identify inefficiencies, provide targeted training, and optimize workflows, directly contributing to improved OEE. Discover the Operator Tool.

Importance of OEE in Manufacturing Efficiency

Overall Equipment Effectiveness (OEE) is a critical metric for measuring the efficiency and productivity of manufacturing operations. It encompasses three key components:

1. Availability: The proportion of scheduled time that the equipment is available for production.

2. Performance: The speed at which the equipment operates as a percentage of its designed speed.

3. Quality: The proportion of good parts produced as a percentage of the total parts started.

OEE provides a comprehensive view of how well manufacturing equipment is utilized compared to its full potential. High OEE scores indicate efficient, high-performing, and quality-focused production processes, while low scores highlight areas needing improvement.

What are the cons of automation?

Job Displacement and Unemployment:

• Automation can lead to significant job losses as machines and software replace human labour, particularly in repetitive and manual tasks. 

Solutions: Reskilling and Upskilling Programs 

OEE Implementation training programs to help workers develop new skills that are relevant in the automated environment. This can include digital literacy, technical skills, and soft skills. 

Initial Implementation Costs:

• The upfront costs of implementing automation systems can be very high with some solutions. This includes purchasing equipment, software, and the expenses associated with training employees to operate and maintain new technologies. 

Solutions: Choose more wisely

Phased Implementation: Implement automation in stages rather than all at once to spread out costs and allow time for adjustment and troubleshooting. Globalreader offers a subscription based model where you can implement our hardware and software gradually. Get started quickly with Hardware + Analytics + Notification bundle starting from 89€ per month.   Continue on with more features like Operator, Planner, Maintenance and Smart Factory.

Technical Challenges and Limitations:

• Automation systems can be complex and require ongoing maintenance and updates. Technical issues, such as software bugs, hardware malfunctions, and integration problems, can disrupt operations and require specialised skills to resolve.

Our solutions? Predictive maintenance

Effortless maintenance for technicians. Establish comprehensive maintenance and support plans to address technical issues promptly. Easily add and manage all machines within a single, user-friendly system. GlobalReader Maintenance allows manufacturers to centralise device data, making it easier to track and plan maintenance tasks. 

Scalability and Flexibility: Choose automation systems that are scalable and flexible to adapt to changes and integrate smoothly with existing systems. Start small but get complete control over the manufacturing process. 

Reduced Human Interaction and Customer Experience:

• Over-reliance on automated systems can lead to a reduction in human interaction, which may negatively impact customer service and experience. Some customers prefer personal interaction and may find automated systems frustrating or impersonal.

Globalreader solutions - Hybrid Approaches

Combine automation with human oversight to maintain a balance. For example, use our automated systems for routine tasks while keeping human staff available for complex and personalised customer interactions. 

Dependency on Technology and Loss of Human Skills:

• As companies become more dependent on automated systems, there is a risk of losing valuable human skills and expertise. This dependency can also make businesses vulnerable to technological failures and cyber-attacks.

How to handle Industrial IoT the Globalreader way?

1. Diverse Skill Development: Promote the development of a broad range of skills among employees to reduce dependency on specific technologies and ensure adaptability.

2. Redundancy and Backup Systems: Implement redundancy and backup systems to ensure continuity in case of technological failures.

3. Cybersecurity Measures: Strengthen cybersecurity protocols to protect against cyber-attacks and data breaches, ensuring the integrity and security of automated systems.

Addressing these cons requires a balanced approach, ensuring that the benefits of industrial IoT and automation are maximised while mitigating its negative impacts through strategies like workforce retraining and robust technical support systems. Globalreader is more than just OEE software provider. We are interested in long-term relations with you so you can scale your business.

Advantages of Automation Technologies

Streamlined Production Processes

Automation technologies streamline production processes by integrating various stages of manufacturing into a cohesive and efficient system. Automated systems can handle repetitive tasks with precision, reducing the need for manual intervention and minimising bottlenecks. This integration allows for smoother workflows, improved coordination between different parts of the production line, and the ability to quickly adapt to changes in production demands. As a result, manufacturers can achieve higher levels of operational efficiency and maintain a steady flow of production.

Reduction of Human Error

Human error is a significant source of inefficiency and defects in manufacturing. Automation technologies drastically reduce the incidence of such errors by ensuring that tasks are performed consistently and accurately. Automated systems follow predefined protocols and algorithms, which eliminate the variability that often comes with manual labour. This leads to higher product quality, fewer defects, and a reduction in waste. Additionally, automated quality control systems can detect and correct issues in real time, further enhancing the reliability of production outcomes.

Increased Production Speed and Consistency

Automation technologies significantly increase production speed and consistency by operating at a pace that humans cannot match and maintaining uniform performance over time. Machines do not require breaks, can work continuously, and perform tasks at a consistent rate, leading to higher throughput. This consistent and rapid production capability allows businesses to meet high demand efficiently and ensures that each product meets the same quality standards. The reliability and predictability of automated systems are crucial for large-scale manufacturing and tight production schedules.

Implementing Industrial IoT and Automation for OEE Improvement

Implementing Overall Equipment Effectiveness (OEE) through Industrial IoT involves several critical steps to ensure a smooth transition and successful outcomes. This comprehensive guide will walk you through each phase, from initial assessment to continuous optimization, highlighting how GlobalReader's tools and solutions can support you at every stage.

Assessment and Planning:

• Evaluate Current Systems: Actually we will help you analyse existing production processes and identify areas where our software can have the most impact.

• Set Clear Objectives: Based on that real-time data you can define specific goals for OEE improvement, such as reducing downtime, increasing performance, or enhancing quality.

1. Technology Selection:

• Choose your plan: Start by selecting our starter bundle, get real-time insight to what is going on in your manufacturing processes and implement extra add-ons like smart-live view.

• Automation Tools: Before you opt for automation solutions such as robotic arms, automated guided vehicles (AGVs), and conveyor systems that align with your production needs you need to know what is happening now in your manufacturing processes. 

2. Infrastructure Setup:

• Network Infrastructure: We will ensure that our hardware is correctly set up and connected to our software. 

• Data Management Systems: Now it’s time to implement data collection and management platforms to handle the influx of data from IoT devices.

3. Integration and Deployment:

• System Integration: Integrate Globalreader hardware and software devices with existing systems and automation tools to create a seamless flow of information and control. 

• Pilot Testing: Conduct pilot tests to troubleshoot issues and fine-tune the integration before full-scale deployment. 

4. Real-Time Monitoring and Analytics:

• Data Collection: Continuously collect data from Globalreader developed sensors and automation systems.

• Analytics: Use advanced analytics tools like operator and analytics to interpret the data and gain insights into production efficiency and equipment performance.

5. Optimization and Maintenance:

• Continuous Improvement: Regularly review data and analytics to identify areas for further optimization.

• Predictive Maintenance: Use our maintenance tool for predictive maintenance to prevent unexpected equipment failures and minimise downtime.

6. Training and Support:

• Employee Training: We are always with you to provide product updates and help you train staff on how to use Globalreader’s automation tools effectively. 

• Technical Support: Rest assured, we provide ongoing technical support to ensure smooth operation and address any issues promptly.

Future Trends and Innovations with GlobalReader's Real-Time Factory Tracking Solutions

1. Advanced Predictive Maintenance

• AI and Machine Learning Integration: Future innovations will see more sophisticated AI algorithms and machine learning models that predict equipment failures before they occur, allowing for proactive maintenance and reducing unplanned downtime.

• Self-Healing Systems: Development of systems that can automatically correct minor issues without human intervention, further minimising downtime and maintenance costs.

2. Enhanced Data Analytics and Visualisation

• Real-Time Big Data Analytics: Leveraging big data to provide deeper insights into production processes, enabling manufacturers to make data-driven decisions quickly.

• Interactive Dashboards: More intuitive and customizable dashboards that offer real-time visualisation of key metrics, trends, and anomalies, making it easier for managers to monitor and improve production efficiency.

3. Integration with Industry 4.0 Technologies

• Industrial IoT Expansion: Broader integration with IoT devices to collect even more granular data from every part of the production line, from raw materials to finished products.

Digital Twins: Creating digital replicas of physical factory assets to simulate and optimize production processes, predict issues, and test changes in a virtual environment before implementing them in the real world.

Achieve higher OEE by leveraging Globalreader

We can say for a fact that our hardware and software can enhance Overall Equipment Effectiveness (OEE) in your factory. Our solutions, such as real-time factory tracking, predictive maintenance, and operator performance tracking, help streamline production processes, reduce human error, and increase production speed and consistency.

As you read from the challenges of automation, such as job displacement and initial costs, you see we can also help you tackle them with phased implementation, and other predictive measures.

Try Our Demo for Free: Experience how GlobalReader can revolutionise your manufacturing efficiency. Get started with our free demo today.