Optimizing Industrial Operations with IoT: A Comprehensive Guide

As Industry 4.0 technology matures, the multiple functional areas (asset management, facility management, plant management, and public works) for organizations must adapt and embrace new solutions that improve efficiency. An area in which efficiency gains can be made with service, inspection, maintenance, and audit processes.

With AI/ML, the path to predictive and efficient operations has arrived. IoT is a key enabler of these operational gains. With IoT, real-time data can be captured on the critical benchmarks of your environment. By analyzing this data, organizations can detect issues early, schedule maintenance proactively, and avoid unplanned downtime.

The IoT operational journey - the end-to-end implementation and deployment of IoT solutions is developed through the following sets of activities:

• Developing the business case
• Determining the IoT device for the use case
• Forming a technical design
  • Connectivity
  • User Experience
  • Cloud Integrations
  • Application

The subsequent sections will expand on each area.

Develop the business case

IoT solutions need to support the right business case. Our research has shown that the two categories of key performance indicators (KPI) that drive IoT business case development are revenue management and cost management.

Revenue management KPIs are critical for any business that relies on the smooth operation of equipment. A well-managed revenue system ensures that downtime is minimized, and production processes run uninterrupted. Whether it's through advanced scheduling, proactive maintenance, or constant monitoring of equipment utilization rates, effective revenue management can significantly reduce the cost of downtime and keep operations running smoothly. Manual processes create a risk to the organization; IoT provides the operational data to support revenue management activities.

Equipment is vital to operations. Conditions monitoring and predictive maintenance are particularly effective methods that allow for detecting potential issues before they become major concerns. By being proactive, organizations can significantly reduce maintenance expenses and improve their operations' overall equipment effectiveness (OEE). Through comprehensive analysis and control, businesses can streamline their processes and ultimately optimize their cost management strategies. This is where IoT can help compliant OEE strategies.

Determining the IoT to use case

In recent years, an increasing number of sensor manufacturers have incorporated Bluetooth low-energy (BLE) IoT over their classic Bluetooth counterparts. The primary reason for this shift is the energy efficiency and longer battery life BLE IoT offers compared to traditional IoT. Designed to consume 10 to 100 times less power, BLE IoT provides a more economical solution when it comes to monitoring and transmitting data. This technology is especially relevant in healthcare, manufacturing, government, and other industrial settings, where devices must operate continuously without requiring frequent battery changes.

In looking at industrial environments, the types of IoT that seemed foundational to predictive maintenance are vibration, indoor air quality (IAQ), leak detection, and temperature. Below is an example of the importance of vibration and temperature devices.

The ISO10816 standard lays out guidelines for vibration monitoring of non-reciprocating and non-rotating machinery. The objective is to detect signs of equipment wear and tear before an unexpected failure occurs. To achieve this, vibration IoT devices are employed to collect data on the different types of vibration experienced by machines. Reliable and accurate data are a prerequisite to establishing maintenance schedules and can significantly extend the life of equipment.

Temperature IoT devices are a critical component in many industrial settings where equipment needs to be kept at consistent temperatures to maintain optimal performance. A properly functioning temperature device is necessary in helping to avoid costly machine damage or downtime due to overheating or overcooling. With advancements in technology, temperature IoT devices have become an increasingly sophisticated and reliable tool, offering exquisite precision to measure temperature variations. These IoT are designed to provide accurate readings and enable companies to measure temperature trends to make informed decisions about their equipment.

Forming a technical design

• Connectivity 

Wireless connectivity decisions are crucial for the success of any sensor network. The ability to wirelessly connect IoT to a network offers many benefits, including flexibility and cost-effectiveness. However, deciding on the appropriate wireless connectivity option can be challenging. Factors such as range, reliability, and power consumption must be taken into consideration when making these decisions. Additionally, depending on the automation objectives, different wireless technologies may be more suitable for a given network. Ultimately, a thorough understanding of the available options and their trade-offs is essential for making effective wireless connectivity decisions in sensor networks.

• Cloud Integrations

As organizations move their applications and services to the cloud, technical decisions related to cloud integration have become increasingly crucial. The integration process involves connecting various cloud systems and applications with each other and on-premises systems to establish seamless communication. Technical teams must evaluate different cloud integration options critically and choose the most suitable one that meets their business needs. IoT will create data that trigger automation workflows. Example workflows include scheduling maintenance, triggering equipment inspections, and proactive monitoring, to name a few. This is a critical area of the end-to-end IoT solution because workflows and cloud integrations are where success is measured.

• User Experience

In today's fast-paced world, the consumption of information is vital for staying informed and making smart decisions. In industrial settings, a vast amount of individuals need access to sensor and predictive maintenance data. That’s where tablets and smartphones provide an interface to access a wealth of information. However, it's not just about consumption; it's also about user experience. The user interface must be intuitive and easy to navigate, allowing users to quickly find and absorb the information they need.

Organizations are looking for robust device management strategies that allow them to manage at scale the delivery of information across web and mobile applications. Device management and application management are crucial for businesses looking to maintain a secure and productive work environment. An intuitive and easy-to-use device management strategy helps businesses ensure that employees have secure access to the tools and information they need to perform their job responsibilities without the risk of unauthorized access. With web and mobile applications becoming the preferred channels of communication in the digital age, by implementing an effective device management strategy, businesses can maximize productivity, cut costs, and minimize security risks.

This is where INFRASI enters. Applying a systematic approach that takes into consideration the entire life cycle of a product, from conception to retirement, we implement an end-to-end solution. With the implementation of a connected worker solution with visual support, the conversion of their manual Standard Operating Procedures (SOP) to digital, predictive models, and augmented reality capabilities, the result is the use of IoT data to drive the best revenue and cost management processes. Let's connect if you want to learn more.