Five use cases for the Industrial Internet of Things (IIoT)

In 2024 manufacturers will be presented with a litany of challenges. Chief among these headwinds are economic uncertainty, continuing shortage of skilled labor, possible supply chain disruptions, and the need for product and process innovation to meet future net zero emissions goals.

It’s not all challenges — there was some fantastic news for US manufacturers in 2023, as they benefited from three significant pieces of legislation in 2021 and 2022 — the Infrastructure Investment and Jobs Act (IIJA), the Creating Helpful Incentives to Produce Semiconductors (CHIPS) and Science Act, and the Inflation Reduction Act (IRA). Inserting funds and tax incentives into US manufacturing sectors record private sector investment in the manufacturing industry. Deloitte reported that “As of July 2023, annual construction spending in manufacturing stands at US$201 billion, representing a 70% year-over-year increase and setting the stage for further industry growth in 2024.”

Answering challenges with innovation

Some of the challenges mentioned above can be turned into opportunities when met with the Industrial Internet of Things (IIoT). The IIoT is comprised of the integration of sensors, software and machinery with internet connectivity to collect, analyze, and act upon vast amounts of data — which enables real-time decision-making and predictive analytics.

In the manufacturing sector, the IIoT helping to transform production floors and planning. Factories can be equipped with IIoT technology to monitor equipment, automate maintenance, and optimize production schedules, reducing downtime and waste. The result can be increased productivity and cost savings. What follows are suggested uses for the IIoT to help manufacturers meet their individual objectives. 

Five use cases for IIoT

1. Sensors and cameras: Environmental sensors and smart cameras can help automate security processes that restrict access to secure areas. Sensors can also give organizations immediate visibility into environmental conditions that can impact productivity. Manufacturers, and their technology partners, can customize sensor thresholds to automatically detect and alert staff members to environmental events. These can include notifications for temperature changes, humidity, water leaks, air quality and more within workplaces, data centers and cold storage environments. Sensors and smart cameras improve sustainability efforts by helping to manage energy usage, and by signaling needed maintenance steps to protect equipment and assets. With the right sensors, users can visualize trends and anomalies, such as energy usage, in an intuitive cloud-based portal.
   
2. Data analytics and AI: Proper application of data analytics and AI reap some of the greatest rewards of IIoT, turning raw data into actionable insights. One of AI’s most valuable aspects is that it confers the ability to analyze large volumes of data. However, a manufacturer's network must be able to accommodate the spikes in traffic caused by the influx of data required to make AI and data analytics work properly. The wide-area network (WAN) must be equipped to collect, transmit, store, analyze and retrieve data to support decision-making. To fulfill these requirements, organizations need a network that can deliver speed, scalability and reliability.
3. Increased efficiency: Because IIoT integrates physical machinery with networked sensors and software to gather and analyze data, manufacturers can boost efficiency. For example, a manufacturing plant leveraging IIoT can predict equipment failures before they occur, signaling that proactive measures need to be taken to prevent unplanned downtime. The IIoT can monitor inventory levels and trigger automatic supplier refilling, thereby easing supply chain headaches that may impact production schedules. Sensors can monitor temperature, humidity, leakage data, intrusion alerts and more to trigger appropriate actions and responses. This approach can drive efficient production from human, machinery and raw materials assets alike.
4. Improved safety: IIoT contributes significantly to enhancing safety standards across various industries. Cameras and sensors can bolster safety and compliance efforts by automating alerts when workers are not meeting personal protective equipment (PPE) requirements or occupancy requirements. Using IIoT systems can help automate dangerous tasks, thereby reducing the risk to human workers. Using the available data manufacturers can anticipate and manage risks, from equipment failures to environmental dangers. By leveraging IIoT, businesses enable the immediate detection of potential hazards. IIoT sensors can detect gas leaks or pressure changes in pipelines, triggering alerts that prompt the proper preventative measures. This not only prevents potential accidents but also protects employees’ health and safety.
5. Cost reduction: Smart cameras and sensors can help manage inventory levels, track assets, and monitor contractors and employees. This can lead to optimizing operations, improved product quality, and reducing unplanned downtime, and so help businesses save substantial amounts of money. In addition, IIoT can help companies reduce energy consumption. By monitoring and controlling energy usage in real-time, businesses can optimize their energy consumption patterns, which can lead to significant cost savings.

Better results through technology

A recent Deloitte study reveals that, through their smart factory efforts, over 70% of surveyed manufacturers use technologies such as data analytics and cloud computing, and nearly half have implemented IoT sensors and devices. The smart factory integrates advanced technologies to provide insights, end-to-end visibility and scalable solutions. The potential benefits of these actions range from gains in efficiency, productivity, and product quality along with increases in safety and sustainability. 

Security concerns of IIoT and smart manufacturing efforts

Not surprisingly, all connected devices can potentially increase the cyberthreat surface. Operational devices are especially vulnerable, as criminals intentionally target assets that are externally accessible. An attack could have grave consequences, and robust security based on the zero-trust model is becoming a must. 

The network for IIoT must be kept highly available. IIoT devices by their nature are numerous and may be spread across many sites and geographies. A managed network can ensure configurations are consistent across locations and that cybersecurity features are automatically and seamlessly updated.

How Spectrum Enterprise can help

Manufacturers can get the technology services they need in one robust solution with enhanced security, delivered by a single partner that makes digital transformation efforts painless.

Find out more about why 80% of Fortune 500 manufacturing companies rely on Spectrum Enterprise for technology solutions, and how Spectrum Enterprise can help manufacturers gain maximum benefits from their digitalization efforts.