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A Complete Guide to PLC Automation

The concept of industrial automation came into being in the early 20th century, long before the invention of Programmable Logic Control Systems. In the early 20th century, factories were usually controlled using electromechanical relays, wherein a switch connected to a device could be turned on or off based on input from an operator. This system was inflexible because it required thousands of relays for simple processes, and if one relay was affected by an error, it could cause that corresponding device to go out of service. Later in 1968, the relay-based system was replaced by PLC, or Programmable Logic Controllers. They were introduced to help industrial plants simplify some of their relay circuitry, which had been difficult to program in the past. The first model was designed with a clear digital display that made programming easy for engineers and technicians already familiar with relay logic and control schematics. The first PLCs were built with limited speed capabilities and storage space. However, modern PLCs have evolved to be extremely powerful with accelerated processing capacity, real-time monitoring, and other features. This blog focuses on PLC automation in today’s industrial world along with advantages, use cases, and the future of PLCs. Continue reading!

 

What is a PLC and Why is it so Important?

A Programmable logic controller (PLC) is an industrial computer used to perform control functions in manufacturing units. This miniature computer contains hardware and software which enables automated control of electromechanical processes. It includes machinery automation on factory assembly lines like the automotive industry, food processing, etc. PLC continuously monitors inter-connected input devices like sensing devices, switches/pushbuttons and makes decisions based upon pre-feed programs to control the state of output devices/machines like valves, pumps, control relays, etc. Further, the compatibility of PLC to withstand harsh industrial environments like extended temperature ranges, electrical interference, dirt, vibration, and other factory conditions make PLC a trustworthy choice among manufacturers.

The increasing usability of PLC in manufacturing industries, machinery automation, handling systems, marine, and various other sectors is rising at a higher pace due to its prominent features like reliable controlling efficiency, sequential control, user-friendly hardware system, ease of programming etc. These unique features of PLC have gained pivotal importance and are ideally suited to the needs of modern automation.

 

Overview: PLC Based automation

The global Programmable Logic Controller (PLC) market was valued at USD 11.21 billion in 2020 and is expected to reach USD 15.15 billion by 2026, at a CAGR of 4.7% over the forecast period (2021 – 2026). PLC is the foundational stone for rapidly growing industrial automation trends as it is vital for industrial control systems. Increased adoption of automation systems is driving the market share of PLC. With AI and IIoT proliferating across every industry, robots have become integral in achieving efficiency in almost every sector. PLC deployment is expected to benefit significantly from the continuous installation of new automated machines worldwide since robots use PLCs for their control system technologies.

Another driving factor of PLC-based automation is its ability to remove human errors during decision-making processes in manufacturing. PLC technology positively impacts the cost of control applications by eliminating the need for hard-wired relays and increasing operational efficiencies. Market studies have observed that the PLC automation system reduces downtime by almost 20% to 4%, driving unparalleled productivity and substantial growth for businesses. There is also a need for real-time process control and speedy application with improved production efficiency, which is made possible through modern automated PLC systems. The processing/scan time of a PLC is around one thousand times per second or 0.001 seconds. PLC Automation is imperative for industrial automation with a broad range of features and ease of use and integration in the industrial setup.

 

Advantages of Using PLC

PLCs offer a wide array of benefits and are the most reliable choice among manufacturers for managing industrial control systems. Below are some of those advantages.

– Ease of Use/Programming: Today, PLCs are becoming more powerful and versatile with increased computing flexibility, built-in wireless capabilities, and greater capacity for delivery. The latest evolution in PLCs directly benefits from USB technology, which makes it extremely easy to program, operate online, and monitor control systems. Moreover, PLCs use simple programming methods like Ladder Logic, Boolean Type, etc. Further, various feature modules can be added to increase the performance of the PLC system or as per the requirement.

– Flexibility with Advanced PLC Technology: PLC software offers a straightforward framework to feed instructions or change instructions as per requirements compared to a relay-based system. Rewiring a whole relay circuit to create a new one is a daunting task, while in the case of PLCs, the logic changes are made inside the controller rather than hardware or wiring changes. The input/output ports can be connected to input and output components to create logic and write a program according to the need of the application. Later the program is downloaded onto PLC software.

– Enhanced Reliability: Once a program is written and tested, it can be downloaded to multiple PLCs to secure the connection in other places with similar needs. The program is stored inside the PLC’s memory, so there is no chance for an error to occur, like in the case of rewiring relays from scratch. It takes a lot of pressure off when it comes down to controlling the overall functionality of the plant with hundreds of machinery/equipment.

– Multiple Points of Contact: PLCs contain a wide range of contact points for each coil available for programming for different applications.

– Effortless Troubleshooting: PLCs have built-in diagnostics and can easily override any software or hardware issues. To find and fix problems, users can view the display of control systems on a monitor and check its execution in real-time. PLC control systems contain many troubleshooting features that immediately inform operators/engineers what’s causing an issue. Fault indicators are displayed, and messages notify the operator of the problem. PLCs are designed to provide easier access, allowing engineers to connect with the components easily.

– Lower Power Consumption: On average, a PLC system approximately consumes only 1/10th of the power compared to the relay-based control system.

– Simulation Feature: PLC programming software entails simulation features to help programmers test the logic development early and check the integration with other devices. With the PLC simulation feature, installation and commissioning can be expedited and a considerable chunk of costs can be saved as errors in development and programming can be detected and rectified at the early stage. Any discrepancies at the execution stage can affect the entire functionality of the factory operation and can cause unnecessary downtime.

– Communication Capacity: PLCs comprise communication capabilities to easily connect with other equipment to conduct various functions such as data gathering, monitoring process parameters, supervisory control, download, and upload programs etc.

 

PLC: Use Cases

The usability of PLC automation systems is dependent on the nature and requirements of the industry. Various sectors use PLC systems to standardize the processes, control operations, and other functions. PLCs have use cases in verticals like- paper manufacturing, aerospace, cement manufacturing, textiles, HVAC, etc. Likewise, in the Glass industry, PLCs combined with Bus technology are used for data recording, maintaining quality control, and positioning control during glass production. Similarly, Oil and Gas industry PLCs on well pads allow technicians to analyze the condition of well pads in different locations based on input and output devices. Later, engineers are sent out to specified well pads that require repairs, maintenance, inspection, etc., without sorting the well pads data manually.

 

The Future of PLC Automation

Programmable Logic Controllers will continue to evolve according to the needs of industrial automation applications. With advancements in technology, PLCs are becoming faster with wireless capabilities and high-speed ethernet, gaining enhanced programming flexibility, scalability, memory space, etc. The future PLCs are likely to get more hardware improvements and upgrades resulting in expanded functionality, continuing to fasten computing capabilities, integration with enterprise resource planning (ERP), and other higher-level computing systems to the factory floor. Data collection from processes and machines has become easier with sorting abilities. The modern PLCs will be manufactured with varied materials like fiber signals for increased durability compared to electronic signals. Combined with IIoT technology, many enhancements in PLC technology have occurred, like compatibility with smart factory environments, remote monitoring, high processing speed with solid-state drives, etc. However, PLCs will also continue to be more optimized and sophisticated as IIoT advancements unfold.

 

Get PLCs for your facility!

Selecting the best fit for your industrial automation needs and adaptability with plant operations is inevitable. Cost, processing speed, communication capabilities, integration with other devices, etc., are some considerations that manufacturers track while making a buying decision for PLCs. However, PLCs come with a wide range of functionality, upgrading capabilities, and other features.

Our engineers at ENWPS can help you with complete PLC supply, installation, commissioning, and programming solutions. Our professionals have qualified knowledge and experience with selection, networking, interfacing, logic development, programming, execution & proving, training & documentation, and other related services. AT ENWPS, our engineers have hands-on experience with different PLC systems like Allen-Bradley, Siemens, Schneider Electric, among others. Leave your requirements at rfq@enwps.com, and over team shall be happy to connect with you!

 

Significance of IIoT Adoption

Adopting IIoT can benefit a manufacturing business owner in innumerable ways driven by a widespread increase in digital transformation and ever-increasing competition in today’s technology-driven world. Through the complete digitalization of the manufacturing process, one can improve operations, limit potential losses, gain visibility into shop floor operations, effectively manage supply chains and empower innovation.

 

Related Blog: Powerful Advantages of Industrial Internet of Things (IIoT) with Industrial Applications

 

Why ENWPS Is a Reliable Choice?

With over two decades of experience providing automation solutions to businesses globally, our engineers have developed a vivid understanding of the company’s challenges during the transition. Our team has worked as an Implementation partner for various projects and provided bespoke solutions per industry-specific needs. Our services range from design & engineering, programming services, supply, installation & commissioning, and IIoT related jobs.

Are you looking for a trustworthy Implementation partner? Your search ends here! Email your requirements to us at: rfq@enwps.com.


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Overcoming Challenges of IIoT Implementation with Professional Experts at ENWPS

Modern facilities are utilizing the Industrial Internet of Things (IIoT) to increase their efficiency and productivity. The IIoT enables real-time data exchange between different equipment, robots, and people through advanced sensors. Major companies across various industries are developing smart factories adopting IIoT in the manufacturing sector. Smart manufacturing allows manufacturers to make environments that require minimal human involvement while ensuring safety and maximum return on investment. Since 2015, the adoption rate of smart manufacturing has been poised to rise swiftly due to the factors such as miniaturization of embedded devices, increasing M2M connections, high volume of data compression and information encrypted for better cyber security, etc. The Industrial IoT market is expected to grow from USD 76.7 billion in 2021 to USD 106.1 billion by 2026, at a CAGR of 6.7% during the forecast period.

The latest technological waves from Industrial IoT are empowering companies to leverage connected manufacturing and analytics for building more robust company-wide data integrity. However, the IIoT brings new security concerns, access control, and network issues.

Let’s look into the challenges and risks involved in implementing and adopting IIoT for manufacturing units.

 

Identifying Common Challenges Faced by Industries

 The challenges faced during IIoT adoption may differ according to the nature of industries, existing circumstances, level of adoption, etc. However, some most common challenges faced by industries are mentioned below.

1. Seamless Integration with Legacy Industrial Systems: The manufacturing environment is flooded with machines and protocols that are not interoperable, creating a difficult challenge for manufacturers. So, there’s a need to design a system suitable to legacy industrial systems that allow all machines to work together and ensure interoperability between them.

2. Security Concerns: Machines are becoming more intelligent than ever through SCADA Systems, M2M technologies, etc. Most connected machines and devices push or transfer data directly to the cloud for real-time analysis – making them vulnerable to security breaches and attacks coming from anywhere in the world via the web. Therefore, as manufacturing processes become increasingly technology-driven, various cyber threats also come into the picture.

3. Inefficient Planning and Lack of Qualified Personnel: Developing a robust IIoT strategy is a vital part of IIoT adoption and implementation. Strategizing the deployment, defining objectives and goals, training personnel, documentation, embracing potential challenges, proper budgeting and planning, finding effective ways of leveraging massive data, security threats, analytics, etc. Many considerations in terms of management, design, and finances require attention to conduct a successful implementation, which a lot of businesses tend to miss out!

Now, let’s look at Industrial IoT solutions that can be incorporated at the planning stage of IIoT adoption to avoid any discrepancies in the future.

 

Solutions to Overcome Challenges

1. Ensuring Seamless Integration and Interoperability: IIoT gateways are a great way to establish communication and interconnect the control systems of an enterprise and existing legacy devices and infrastructure. IoT Gateways essentially do what their name implies – they act as a conduit between machinery/equipment. Many organizations implement IIoT gateways to help adapt new equipment in existing networks. For instance, it can connect SCADA systems/ DCS with the cloud using industrial protocols like; MODBUS, PROFIBUS, etc.

2. Addressing the Security Concerns of IIoT Execution: Prioritizing security solutions from the initiation of IIoT implementation can help businesses combat security concerns. Incorporating security-by-design protocols, deploying monitoring and cybersecurity tools, encrypting data transmitted from connected devices, access management within cloud databases, etc., can help address the security concerns. Moreover, to ensure hardware security, manufacturers can make use of TPM (Trusted Perception Module), TTM (Trusted Terminal Module), and TNM (Trusted Network Module) to overcome security issues.

3. Goal Setting and Tracking: Before the actual IIoT implementation, it is quintessential for businesses to align the technology developments/advancements with the organizational goals and define metrics to track growth at each adoption stage. It will add in ROI calculation and help managers identify mismanagement if any. Further, fostering a positive attitude towards change within the organization can garner impeccable benefits.

Another essential aspect of successful IIoT adoption is selecting an Implementation Partner or IIoT advisor over a vendor. An Implementation Partner would support system integration, help decide priorities, provide personnel training, assist with overall reinforcement, help create a strategy, etc., which a vendor possibly won’t offer.

 

Significance of IIoT Adoption

Adopting IIoT can benefit a manufacturing business owner in innumerable ways driven by a widespread increase in digital transformation and ever-increasing competition in today’s technology-driven world. Through the complete digitalization of the manufacturing process, one can improve operations, limit potential losses, gain visibility into shop floor operations, effectively manage supply chains and empower innovation.

 

Related Blog: Powerful Advantages of Industrial Internet of Things (IIoT) with Industrial Applications

 

Why ENWPS Is a Reliable Choice?

With over two decades of experience providing automation solutions to businesses globally, our engineers have developed a vivid understanding of the company’s challenges during the transition. Our team has worked as an Implementation partner for various projects and provided bespoke solutions per industry-specific needs. Our services range from design & engineering, programming services, supply, installation & commissioning, and IIoT related jobs.

Are you looking for a trustworthy Implementation partner? Your search ends here! Email your requirements to us at: rfq@enwps.com.


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IIoT in Manufacturing: Importance, Advantages, Smart Use Cases and More

 

The manufacturing industry is currently undergoing a burgeoning digital transformation globally. The new age information technologies and operational technologies are transforming facilities into more innovative, faster, and more scalable units. From maintenance, supply chain operations, industrial asset tracking, process optimization, human resource management to barring none of the activities, IIoT solutions are bringing about the rapid transition through continuous improvement. Industrial Internet of Things has opened a plethora of opportunities for businesses to use the valuable real-time data for their win! IIoT empowers personnel at all levels to detect problems and inefficiencies beforehand. This data-driven decision-making takes the guesswork out from solving problems and optimizes operations, resulting in cost reduction, enhanced visibility, better facility management, etc.

 

The Competitive Edge of Implementing IIoT

In an effort to uncover new ways of strengthening manufacturing processes, businesses worldwide are resorting to digital transformation led by IIoT. The recent industry trends are headed towards becoming digitalized, focusing on becoming service-centric over product-centric, and adopting cybersecurity measures. Precisely, this is where IIoT for manufacturing comes into play.

An executive summary by Forbes Insights mentions that “Digital transformation sits atop the strategic agenda for enterprises, according to a Forbes Insights and Hitachi survey of 573 top executives worldwide. The next two years are critical in this regard, as half of them believe that their organizations will be vastly digitally transformed in that time.”

However, early adopters are already leveraging Industrial Internet of Things solutions and witnessing drastic positive change in overall plant and business efficiency, as emphasized by Bsquare in its annual IIoT maturity survey. It reports that 86% of manufacturers have already adopted IIoT solutions, and 84% of them find IIoT extremely effective.

 

IIoT Adoption in Manufacturing Units

For successful adoption and implementation of IIoT in manufacturing, the four pillar IIoT components need to be incorporated as stated below:

1. Intelligent asset: The primary role of these assets is to enable connectivity and sustain continuous data gathering for analytics. Sensors, edge devices, IoT gateways, embedded systems, and other built-in-intelligent equipment form the foundation for intelligent assets.

2. Data Communication Infrastructure: Data Communication between these assets and other entities requires network technologies such as LTE, Zigbee, and Wi-Fi. However, often IIoT systems are deployed via cloud-based computing infrastructure to maintain extensive data requirements.

3. Software/Application: To equip factory personnel with an easy, reliable, and flexible interface to interact with IIoT systems and interpret gathered data, software, or applications plays a significant role.

4. Human Resource: The operators or managers involved in interacting with the IIoT system, monitoring performance, and making decisions, create the impeccable part of the successful adoption of IIoT. Therefore, personnel training and selection shouldn’t be overlooked while adopting Industrial IoT solutions.

 

Significant Advantages and Influence of IIoT

1. Enhanced Industrial Machinery/Equipment Utilization: Ensuring each equipment and machine in the industrial setup is utilized up to an optimum level and is in good health might seem a herculean task when done manually. But, with Industrial IoT based machine/equipment management, overall equipment effectiveness (OEE) and overall process effectiveness (OPE) can be easily measured and maintained at each manufacturing stage. It will result in lesser downtime, and increased output.

2. Just in Time Manufacturing: Real-time data reporting makes Just in Time manufacturing possible. Having up-to-date and prompt information allows manufacturers to make crucial economic, process, and quality decisions that affect the entire production line and end-product. Operations can be adjusted via live data to eliminate waste and ensure that production is finished in time to coincide with raw materials availability and planned timelines.

3. Market Forecast: A manufacturing facility must implement the required steps to prepare for any impact on products/services. For this purpose, IIoT solutions enable effective data mining and help generate actionable insights from it. Data from all over the enterprise provides visibility into manufacturing management, operational quality management, product and customer preferences, inventory, costs, output patterns, etc. This predictive analytics enables the optimization of businesses for overall success.

4. Inter-connecting Remote Assets: Connecting devices means that data from remote assets are now accessible from a central location. This gives more remote control over what’s going on at/in the plant. For example, one can check in on inventory and make changes to pricing or stock when necessary, based on data collected from what’s happening on-site. It facilitates the process of monitoring and securing assets. This equates to greater control over remote resources located in disparate areas, making them easier to oversee from afar.

Some other benefits of IIoT implementation involve reducing lead time, optimizing factory management, industrial process monitoring, enhancing the quality of products, etc. IIoT based solution is potent and can create significant operational, financial, and managerial benefits.

 

Use Cases: How Are Industries Leveraging The Power of IIoT?

From maintenance, monitoring, process optimization, asset tracking, or any industry-specific task, IIoT based solutions can help streamline and manage the overall operations/activities. Below are some of the frequent and essential use cases of IIoT;

– Condition-Based Maintenance: A key feature of an IIoT solution is the use of real-time data collected from the various sensors and actuators within a manufacturing plant. By streaming this data over the internet and analyzing it, operators/ maintenance engineers can develop detailed usage and status reports about equipment. This kind of information can tell precisely how assets and machinery are being used to assist in planning future ventures and improve efficiency within the company’s overall assets, thus improving the lifespan of machines.

– Enhancing Quality and Assisting in Inspection: The importance of quality inspection cannot be denied when it comes to manufacturing. It gives operators/engineers an upper hand in catching defects early before they become a big problem and allowing them to be resolved before they interrupt the further process. IIoT solutions incorporate IIoT devices such as machine vision cameras, scales, calipers, and temperature/humidity sensors connected with intelligent sensors to increase precision in the inspection process.

Apart from the above-mentioned Industrial Internet of Things use cases, the objectives achievable through IIoT solutions are limitless. These solutions focus on industry-specific needs and hold immense potential in data gathering, monitoring, and analyzing as per requirement—for instance, vibration monitoring for milling machines, condition monitoring of fluid cooling systems, etc.

 

Accelerate Your Business with IIoT

It’s not an exaggeration to say that Industrial IoT exposes a business to innumerable growth opportunities, aids in quality management, and maximizes profits. However, every business is unique, so the implementation and adoption of IIoT solutions differ to ensure that all the efforts are made to drive innovation in the most impactful areas of the business.

If you are a business looking to elevate your manufacturing unit, our experienced engineers at ENWPS can help you! From IIoT, automation solutions to professional design and engineering services, our engineers possess rich experience in various industry verticals to help businesses achieve newer heights.

Talk to us today! Reach us on automation@enwps.com


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Powerful Advantages of Industrial Internet of Things (IIoT) with Industrial Applications

Industrial Internet of Things (IIoT) is the new wave of technology innovation impacting the way manufacturing facilities function. The IIoT, using sensors, advanced analytics, and intelligent decision-making, profoundly transforms how field assets connect and communicate within the enterprise. Moreover, deploying Industrial IoT solutions is more than integrating devices into the network. It is about how managers/operators use that network to make the business work better –achieving higher production efficiency, becoming more predictive, and more capable of delivering on customers’ expectations.

In the ambit of cut-throat competition, businesses are constantly looking for opportunities to outperform their rivals; therefore, embracing new technology like IIoT becomes inevitable. Companies are also experiencing enormous financial and production efficiency advantages by implementing Industrial IoT solutions, leading to its widespread adoption. The global forecast suggests that the market size of the Industrial IoT (IIoT) market will be worth $263.4 billion by 2027 from $76.7 billion in 2021.

 

Compelling Benefits of IIoT

The Industrial Internet of Things technology possesses the immense potential to efficiently streamline processes, cut down on costs, reduce downtime, increase productivity, and lead to an efficient workplace. Moreover, the possibility of IIoT to gather real-time data, convert them into actionable insights, automate and optimize operations, anticipate scenarios, etc., results in unrivaled gains. Below we have explained some key benefits of IIoT.

– Production flow monitoring

Production flow monitoring is a vital part of industrial process management as it directly impacts an enterprise’s cost and quality goals. By automating the optimization and efficiency tracking process of production lines and machines through IIoT technology, businesses can identify and reduce bottlenecks to an optimum level as it’s essential to check performance at every stage. By doing so, engineers can track the quality of parts being manufactured and reduce overhead costs of scrapping and rework.

– Enhanced operational effectiveness

Cloud computing, edge devices, big data and analytics, etc., are improving the operational intelligence of industries, allowing them to enhance overall effectiveness. From equipment monitoring to predictive maintenance, product quality checks, software-driven systems, supply chain management, gathering real-time plant efficiency KPIs, decentralization of decision making, etc. IIoT solutions empowers industries to garner optimal outcomes in the lowest possible time.

– Increased flexibility and agility

With the ever-growing demands of consumers and changing market trends, it is quintessential for companies to adapt to technology changes as quickly as possible. In a global survey of around 1300 CEOs, 59% of the respondents claimed that “acting with agility is the new currency of business; if we’re too slow, we will be bankrupt.” Industrial IoT solutions and technology provide businesses the opportunity to respond to these changes by allowing customization, ease of reprogramming, and cutting costs of reconfiguration every time a new project initiates.

– Improved safety compliance

Industrial IoT solutions result in a more connected, optimized, automated, and risk-free working environment in industries leading to reduced exposure of humans to hazard-prone situations. In most cases, operators feed data/instructions to the machines and remotely monitor the entire process, eliminating the need to be physically present at the manufacturing setup. Besides, using smart sensors, variables like temperature, smoke, vibrations, etc., are controlled and reviewed continuously, and if any failure occurs, the system triggers an alert/alarm.

 

Industrial Applications of IIoT 

To help understand how businesses are transforming the benefits of IIoT for their win, below, we have gathered some consistently used industrial applications of IIoT. However, unique fusions of Industrial IoT solutions need to be incorporated according to industry-specific requirements and organizational goals to gain optimal results.

– Condition-based maintenance

When combining IIoT devices with manufacturing equipment, the benefits are endless. Equipment like sensors can record temperature, pressure, speed, materials used for manufacturing, check on problematic operating conditions, etc. Further, through data analytics, factory managers can access real-time information regarding the status of machines, increase operational efficiency, and reduce downtime due to inadequate machine maintenance. It also aids facility management as managers will be aware of how staff are using equipment or performing in specific environments that could be detrimental to products’ health—ultimately maintaining product quality.

– Predictive maintenance (PdM)

When maintenance in the manufacturing world lacks innovation, it can become a reaction rather than a proactive measure. In this case, manufacturers are left trying to identify the problem and resolve it while simultaneously using internal resources to identify existing solutions. But if this isn’t working, they might have to spend money on an external source to do something about it. With predictive maintenance powered by Industrial IoT solutions, manufacturers will be able to reduce the occurrence of such a problem because each equipment and machine are continuously monitored accordingly. Even before any problems occur, they will be able to take the necessary steps to prevent them from happening. E.g., drone technology is being used by many manufacturers to detect malfunctions in powerline networks. These drones are equipped with atmospheric sensors and equipment that can monitor the status of power-conducting lines, assess risk, anticipate issues, measure voltage fluctuation, and more! It allows avoiding costly maintenance or repair.

– Fleet management

Transportation/shipping costs can be significantly minimized or controlled by using a fleet management system as part of a company’s business model. By deploying software-driven Industrial IoT solutions, businesses can accurately record each vehicle’s/vessesl’s daily commute, transfer, maintenance, and replacement history. This way, companies can streamline their vehicle investment and track shipments while increasing productivity and ensuring on-time deliveries.

– Preventing supply chain errors

IoT applications are great for tracking events across the supply chain. They reduce the chances of errors during inventory management and check production flow by better understanding a company’s daily performance. Moreover, by deploying a software-based approach, users receive notifications of essential changes in the overarching plan and updates. It results in enhanced visibility and decision-making based on data and helps manufacturers predict potential issues that may go unnoticed.

– Energy management

Industrial processes often use plenty of energy, so even minor improvements in energy management can help industrial companies save a lot of money and improve their environmental performance – and that’s precisely where Industrial IoT solutions come in. IIoT devices like smart sensors are a great way to keep track of electricity and power usage throughout the facility. Managers can use this information to determine the energy usage of every equipment/machinery of their system, allowing them to make appropriate changes as per requirements. This improved visibility can help companies boost revenue by using energy more efficiently and identifying areas where renewable energy can be added.

To know more about IIoT, read blog: Explained: Everything that Businesses Need to know about Industrial Internet of Things.

 

Wrapping it up       

IIoT is here to stay and will change the world of manufacturing. It’s creating a better tomorrow with smart technology and integration. The world is at the cusp of the most significant industrial revolution ever, driven by the convergence of information and operations. IIoT is bringing in the next wave of industrial automation to help businesses achieve new milestones and reach higher performance levels. IIoT is the future of smart factories and smart manufacturing.

 

Let’s elevate your enterprise!

The field of IIoT is vast, and it’s important to create a robust strategy for implementation to gain the most out of it. However, it also involves huge investment and with this comes greater risk. Therefore, it’s important to consider all the factors and involve ROI metrics while drafting IIoT implementation strategy, to get better results. At ENWPS, we understand the criticality of IIoT transformation and hence provide reliable IIoT solutions backed with rigorous analysis and technology expertise.

Need quick assistance? Get in touch at: rfq@enwps.com


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Explained: Everything that Businesses Need to know about Industrial Internet of Things

 

For quite a time, the Industrial Internet of Things has been a trending topic among businesses and tech enthusiasts on the web. Many ground-breaking developments are happening in the Industrial Internet of Things sphere. The IIoT allows industrial assets to be monitored and controlled remotely across existing network infrastructure, creating opportunities for more direct integration of the physical world into computer-based systems. It improves operational efficiency, accuracy, and economic benefit and reduces human intervention. This blog brings to light all the information businesses need to know about developments and potential gains of the Industrial Internet of Things.

 

What is IIoT- Industrial Internet of things? 

The Industrial Internet of Things is a revolutionary technology connecting people, processes, and products to accelerate the digital transformation of facilities. IIoT is the collection of sensors, instruments, and autonomous devices connected through the Internet and automated to industrial applications. It forms an industrial framework in which all the equipment and machines are interconnected and synchronized through big data/analytics, cloud computing, mobile devices, and software tools to collect, monitor, exchange, analyze, and operate on data to leverage potential. The IIoT technology has strengthened and reformed machine-to-machine communication to create a more agile, scalable, error-free, and optimized factory environment.

 

IIoT technology and How it Works?

The Industrial Internet of things is a massive network of connected devices that forms a system for managing and sharing data within an industrial setup.  The uniqueness of the Industrial Internet of Things lies in the intersection of information technology (IT) and operational technology (OT), which is transforming industries into intelligent systems. OT encompasses networking of all the manufacturing processes and equipment through industrial control systems (ICSs), human-machine interfaces (HMIs), supervisory control and data acquisition (SCADA) systems, distributed control systems (DCSs), and programmable logic controllers (PLCs). At the same time, IT consists of smart connected devices containing computing capabilities. These devices sense, aggregate, communicate and convert data into actionable insights through the application of big data/analytics and wireless networks. These insights help factory managers and operators to optimize shop floor operations.

 

Unlock Potential Benefits of Implementing IIoT

With the advent of intelligent IIoT devices and IIoT technology, monitoring and tracking the smallest devices to the complex processes has become a reality. It has enabled businesses to make better decisions and streamline the entire process to enhance enterprise efficiency. IIoT solutions eliminate operational discrepancies by making informed predictions about possible breakdowns and bottlenecks in the equipment or system, further empowering organizations to elevate business performance.

Below are some of the most rewarding benefits of IIoT that businesses can capitalize on to achieve maximum operational efficiency.

 

  1. Predictive maintenance and reduced machine downtime

Logbooks are an efficient way of maintaining machines for specific tasks such as changing the oil and cleaning out mechanics.  But what happens if a machine or device suddenly breaks? A study by Aberdeen says that unscheduled downtime could cost companies as much as $260,000 per hour. With the help of IIoT devices and solutions, the possibility of sudden breakdowns is eradicated as it tracks any anomalies or uncommon equipment behavior before they hamper the production processes. IIoT enabled predictive maintenance incorporates keeping a close check on historical machine performance to predict potential machine downtime.

2. Efficient management of supply chain and improved visibility

Suppliers, manufacturers, and customers can use management systems to control complex supply chains by getting updates about the availability of raw materials, tracking manufacturing cycles, tracing location while shipment, etc. This way, they can better determine if there’s been an issue with inventory or a potential situation that could damage their products. By incorporating IIoT technology or software-based tracking, instant visibility can be achieved, allowing everyone involved to react immediately or accordingly, depending on the nature of the problem at hand. Moreover, it will also aid in meeting client expectations and making on-time delivery of goods.

3. Asset tracking and optimization

By applying the IIoT solutions for a connected asset ecosystem and advanced solutions to monitor/visualize these assets, a range of new possibilities opens up, and enterprises can gain enormous benefits. Logistics, warehousing, production, transportation, in-house machines and equipment tracking, managing staff roles and operations, etc., can be managed and effectively controlled by applying IIoT technology. It will result in effective planning and scheduling, optimum utilization of assets, improved workflow, and bridging the gap between ground-level operations and executive departments.

 4. Enhanced quality control

Quality control professionals understand that it is much better to identify a potential issue early than to discover it at a later stage of production. By deploying IIoT solutions, continuous stepwise tracking of manufacturing processes is accomplished, resulting in improved quality of products, reduced wastage of raw materials, and eliminating rework and scrapping. Moreover, with the help of data collection, future processes can be optimized accordingly for enhancing quality standards.

5. Improved safety and work environment

IIoT can improve safety and make the industry environment more compliant in manufacturing plants. IIoT solutions like automated alert systems and sensors monitor energy consumption, temperature, moisture, and excessive pressure levels preventing potential catastrophic events like fires or explosions. They also monitor the proximity of workers to large machinery for the same reason – making manufacturing plants safer for staff.

 

Why do Businesses can’t Afford to Ignore IIoT? 

The manufacturing world is constantly transforming by the lightning-fast data flows that can produce a wealth of information about products, their use over time and are paving the way for better optimization of processes. IIoT solutions are helping businesses gain insights to enhance scalability, performance and eventually create robust systems with the highest operational efficiency. More than a necessity, IIoT solutions have become a way of doing business if willing to maintain a competitive edge.

McKinsey estimates that the economic impact of IoT could be as much as $6.2 trillion by 2025. And possess the potential to drive productivity across $36 trillion in operating costs across multiple industries, including manufacturing and other sectors.

Moreover, worldwide, GE thinks a 1% improvement in industrial productivity could add $10 trillion to $15 trillion to worldwide GDP over the next 15 years.- Chunka Mui, Forbes.

 

Industrial Applications of IIoT that Businesses are Already Leveraging

One real-world industrial application of IIoT inspiration can be derived from an industrial automation leader, ABB, making effective use of IIoT technology to monitor and maintain its robots. By incorporating connected sensors and edge devices, the maintenance engineers conduct repair and maintenance tasks well in advance to ensure smooth production workflows and reduce risks of downtime or costs of breakdowns.

Another instance is from Rolls-Royce: Pioneering Cutting-Edge Technologies, ingeniously leveraging IIoT technology for the future of engine maintenance. It is working on a revolutionizing technology, swarm robots. These mini-robots are around 10mm in diameter, with cameras deployed, and can crawl through the engines for visual inspection. It will aid engineers with predictive maintenance and visual inspection of an engine without removing it from the aircraft.

Various companies are testing and developing next-generation technologies for transforming their enterprises into automated, intelligent, and interconnected systems.

 

Future Potential of IIoT 

The Industrial Internet of Things will play a significant role in enabling digital transformations in the future. Big data analytics will evolve to detect conditions in real-time and respond quickly. Likewise, production lines and supply chains will be full-fledged digitized for greater efficiency and throughput. Industrial operations may use thousands of 5G connected devices in the future. Moreover, 5G will affect the implementation of IIoT solutions, likely resulting in device proliferation. 5G’s higher bandwidth and lower latency frequencies make IIoT devices ideal for being used in remote sites while it was previously impractical because of the lack of a high-speed connection. In upcoming times, more businesses will use 5G connectivity as running a cable is cost-prohibitive in various cases, but with 5G wireless technology, getting rid of those cables becomes a feasible option. Connectivity, agility, scalability, less human intervention, optimization for zero defects, better decision-making capabilities, analyzing historical data for process optimization, etc., will be the critical drivers of deploying IIoT solutions.

 

IIoT and Security Challenges 

There are several aspects that organizations need to consider when embracing IIoT implementation. IIoT brings many benefits to businesses today, but it also has cyber security risks. A survey by tech analyst Gartner found that security is one of the most significant areas of technical concern for organizations deploying IoT systems – primarily because they don’t have complete control of the software and hardware being used. Companies need to understand what these risks are, how to prevent them, and how to minimize the damage if a security breach does occur. Deploying measures for secure communication between machines, including security monitoring and analysis systems for preventing cyberattacks, data encryption, safe execution environments, validation and authentication between sensors, gateways, and the software orchestration platform, can be implemented to address security challenges.

 

Elevate Your Business with IIoT Solutions 

ENWPS has the knowledge, skills, and standards-based expertise needed to offer a wide range of connected equipment along with mobile solutions. Using Plantminder and enabling mobile devices of this software allows the FSEs to collect and process data on location.  Faster troubleshooting, data analysis for new product developments, efficient equipment maintenance, process optimization, etc. Regardless of what goals your organization wishes to achieve, ENWPS can make that happen by providing IIoT solutions and design & engineering services.

Upscale with expert support. Get in touch at: rfq@enwps.com!


About ENWPS


ENWPS has a two-decades legacy of providing innovative Automation and Robotics solutions – from concept to implementation, providing quality and comprehensive innovative systems coupled with technology expertise.

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3rd Floor, Godrej Eternia-C, Wakdewadi,
Shivaji Nagar, Pune 411005, India


+91 96376 03230

rfq@enwps.com


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