IoT is becoming an inseparable part of the manufacturing industry. What can be done by combining manufacturing and IoT, and what benefits does it bring? We will introduce the relationship between manufacturing and IoT, and examples of IoT initiatives in the manufacturing industry.
What is the relationship between manufacturing and IoT?
The manufacturing industry and IoT have a strong affinity, and the use of IoT is becoming a matter of course for the manufacturing industry. How has IoT been adopted in the manufacturing industry?
The expanding meaning and role of IoT
IoT is an abbreviation for Internet of Things, and in Japan it is called "Internet of Things". Traditionally, only limited devices such as computers and mobile phones were connected to the network. However, with IoT, all things can be connected to the Internet, and the data obtained from it makes it possible to understand the status of things and operate them from a distance.
Sensors are used to collect data. Conventional sensors cannot detect detailed data, and even if they could, the data is large, making it difficult to send and receive. Furthermore, if data was sent from sensors attached to all things, it was impossible for conventional communication networks to handle it.
This problem was solved by the development of sensor technology and the evolution of network (communication) technology. It can be said that these technological advances have made the practical application and spread of IoT possible.
The use of IoT is not limited to visualizing information and remote operation. Data collected by IoT is accumulated as big data, and the possibilities for its use are further expanded by analysis using AI. As it is called the Internet of Things, IoT was previously only applied to things, but its possibilities for use are becoming even greater. People's movements, the contents of their work, and the complex connections between them are also changing to be used by IoT.
The connection between manufacturing and IoT
Traditionally, the use of sensors has been important in the manufacturing industry. Control devices such as PLCs and industrial PCs cannot function without signals sent from sensors. The use of sensors has been essential in automating production. In this way, IoT has been adopted in the manufacturing industry, where the use of sensors and data has been widespread, as soon as it appeared. For example, by introducing IoT technology to manufacturing machines, it is possible to obtain information on operating status and quality data, and visualize and analyze them. Furthermore, IoT technology has become indispensable for the manufacturing industry in order to improve production efficiency.
In the 2017 Ministry of Economy, Trade and Industry's "Manufacturing White Paper ," the manufacturing department was the most common, at 44.8%, as the "department leading data collection and utilization." Such data collection and utilization using IoT has become widely adopted not only by large companies but also by small and medium-sized enterprises. However, since the subsequent 2018 survey , the central department responsible for data collection has shifted to the management and business strategy departments, and the percentage of companies working on data collection has decreased in the 2019 survey . Furthermore, the 2020 survey showed that the percentage of companies that actually utilize data has not increased, highlighting the fact that data utilization is a challenge for Japanese companies.
As such, while there is great potential in using data through IoT, it can be seen that adoption has not progressed beyond a certain level. The link between manufacturing and IoT can greatly improve productivity in manufacturing. Due to such major changes in the industrial structure, it is said that the use of data through IoT will be the fourth industrial revolution.
Benefits of using IoT in manufacturing
What are the benefits of introducing and utilizing IoT in the manufacturing industry, and what will be possible? There are various possible ways of using it depending on the industry and business model, but the following are some of the benefits common to the manufacturing industry:
Automation, labor saving, and manpower saving in production processes
Typical examples of automation in the manufacturing industry include the automation of transport processes using transport machines and the automation of processing processes using robots. Conventionally, these types of automated equipment performed fixed operations according to set programs. However, IoT allows the status of equipment to be grasped in real time, making it possible to quickly respond when problems occur. In addition, processes that previously required on-site manual work or visual supervision can now be operated and monitored remotely. This allows workers to be responsible for multiple sites, promoting labor and manpower savings. In this way, IoT makes it possible to automate production processes and realize labor and manpower savings.
Achieving predictive maintenance and improving operation rates
With IoT, it is possible to detect signs of abnormalities by analyzing data sent from each part of the equipment, and to prevent problems from occurring in advance. By analyzing collected data with AI, it is expected that the accuracy of trouble prevention will increase, and it will also become possible to deal with problems when they do occur. By detecting signs of machine failure early, it becomes easier to set the timing of maintenance as desired. Maintenance can be performed on days and times when the machine is not scheduled to be in operation, ensuring the uptime of the machine.
Utilizing data to improve operations
Data collected by IoT can be used not only to see the real-time situation, but also to improve operations by accumulating and analyzing it. The movements of people and objects on-site can be grasped using wearable devices and IC tags, and this can be used to improve the efficiency of traffic flow and movement volume. In addition, data sent from sensors on tools and equipment can be collected for work in the production process, and data can be accumulated by analyzing people's movements using image processing. The analysis results can be used to standardize operations and consider more efficient work methods.
Use in product development and business model innovation
Incorporating IoT into your company's products and manufacturing technologies can lead to the development of new products. Many companies have already developed products that incorporate IoT to add functions such as remote monitoring and operation. In addition to directly adding functions like this, IoT can also be used to provide after-sales services and propose better products by analyzing usage. In addition, using IoT within your company may help you differentiate the products and services you manufacture from those of other companies. Using IoT can also help establish new business models that have never been seen before.
Key points for introducing IoT into manufacturing
When introducing IoT into the manufacturing industry, you can expect better results by paying attention to the following points.
Clarifying the problem and objectives
Before introducing IoT, it is necessary to clarify why IoT is necessary and what problems you want to solve with IoT. If these things are not clear, you will not be able to fully utilize IoT and will not be able to achieve the benefits of introducing it. In order to clarify the purpose of introduction, start by conducting a work analysis in the production process and identifying issues for each process. From here, consider what kind of IoT technology can be introduced to solve the issues.
In this way, it is important to clarify the issues and purpose before introducing IoT.
Step-by-step IoT adoption
Introducing complex IoT technology all at once can not only cause confusion on the shop floor, but can also result in lower production efficiency. It is also necessary to consider that there will be a certain number of employees who are averse to new systems and work methods. In order to start using IoT without making these problems worse, the introduction will proceed in four stages: data collection, accumulation, visualization, and analysis.
Sensors and cameras are installed on production equipment to prepare the data collection environment.
Next, a place to accumulate data is secured. At this time, it is also decided whether to accumulate it in the cloud or store it in-house. If improved processing speed and data security are required, we recommend using edge computing, which enables distributed processing.
From the data accumulated in this way, we will proceed to visualize the production status using a system. It will be possible to grasp the real-time situation even during setup or when an abnormality is detected.
The accumulated data will then be analyzed and used to discover the next issue and solve the problem.
By selecting and introducing the appropriate solution for each of these four stages, it will be possible to build a system that suits your company's production scale and business type.
Evolution and deepening of data utilization methods
By implementing these four stages, it is possible to build a system that is easy to use on-site, and ideas for improvement to further improve efficiency will also emerge. Rather than simply visualizing the data and being done with it, the benefits of implementing IoT can be further increased by thinking about future uses, such as repeatedly improving issues and applying them to new business ventures.
Manufacturing Industry's IoT Initiatives
The manufacturing industry and IoT are highly compatible, and their introduction and utilization have produced a variety of benefits. However, even within the manufacturing industry, the use of IoT varies greatly depending on the characteristics and type of product, and the manufacturing process and method. The introduction of IoT in the manufacturing industry is becoming the norm, but there are also many companies that are taking their use of IoT a step further than simply visualizing production status. Let's take a look at some examples of how manufacturing companies are utilizing IoT.
Combining craftsmanship with IoT to shorten work time
At a long-established dyeing factory, test materials are dyed as sample tests before receiving an order. Previously, this process took about two weeks, and there was a risk of missing orders due to a lack of dyeing containers during busy periods. In addition, color mixing was done based on the craftsman's intuition, resulting in subtle errors.
This is why a business management system and CCM (Computer Color Matching) were introduced. By registering the dye and material patterns in the CCM system, the judgments that were previously based on the craftsman's intuition were replaced with digital data. This has led to the standardization of dyeing quality and a significant reduction in work time. In addition, the business management system centrally manages order contents, delivery dates, and work status, making it possible to grasp the progress status within the factory.
Sensors detect and eliminate causes of defects
Factories that manufacture sensors, which are essential for IoT, have also succeeded in improving efficiency by further promoting the use of IoT. A company that manufactures high-precision industrial sensors has created a system that uses a production management system to automatically order the 10,000 parts handled during production. At the same time, it has enabled proper inventory management and the supply of the necessary parts at the necessary time.
By automating these tasks, they have succeeded in creating time for creative work, such as manufacturing and improving products with high added value.
Prevent mistakes by implementing IoT in manufacturing instructions and production systems
A company that makes additives (masterbatches) required in the manufacturing process of resin products used to work according to manufacturing instructions printed on paper. Numerous raw materials were weighed, recorded, mixed, and inspected manually, but human error was an issue. By introducing a weighing system using IoT technology and linking it to the core system, manufacturing instructions were also automated. This reduced the incorrect use and weighing of raw materials, and records were automatically input and output, reducing man-hours and greatly improving labor productivity.
IoT makes heat treatment furnace operations visible and speeds up response
In a company that performs heat treatment of metals, it was necessary to frequently check the operation status of unmanned heat treatment furnaces at night in order to deal with the situation when they stopped due to a problem. By introducing an IoT monitoring system, the administrator can now monitor and operate the furnace remotely. It has also succeeded in increasing safety by enabling the furnace to be stopped immediately in the event of an emergency such as a disaster.
Efficient product management by directly connecting manufacturing machines and production management
Companies that perform plastic molding have introduced molding machines from multiple manufacturers and have been managing their data on paper. In response to this situation, the newly introduced production management system can connect to molding machines from different manufacturers and can also accumulate and analyze production data. Data analysis makes it possible to forecast future orders and manage inventory appropriately, and the efficiency of production management work has improved the accuracy of the entire production system.
IoT will dramatically change the manufacturing industry
IoT is already transforming the manufacturing industry, and it is expected that the way data is used in production will continue to become more important in the future. Collecting data from machines and equipment used in production is a given, and whether or not that data can be used will have a major impact on productivity.
In the manufacturing industry, where productivity varies greatly depending on the production cycle, real-time performance will also be required in data utilization. Since the real-time performance of data affects the operation of manufacturing equipment and robots, the processing and transmission speed in IoT is important. At this time, edge computing is attracting attention as a technology that enhances the real-time performance of data. By combining IoT and edge computing, data utilization in the manufacturing industry can have even wider possibilities.
For an overview of edge computing, please also refer to this article:
Why is edge computing attracting attention? What is the difference between cloud and on-premise? | Stratus Blog
