Internet of things and its importance for the industry

Internet of things and its importance for the industry

The world is rapidly moving towards a new era, the hallmark of which is the emergence of IoT technologies. Familiar devices such as refrigerators or cars have learned to connect to the network and exchange data without human intervention. Software, hardware, communication infrastructure, as well as “connected” devices participating in the data exchange process, are combined into a technological ecosystem called the Internet of Things (IoT).

The widespread use of the Internet of Things is fueled by the massive emergence of devices equipped with electronic components, software, and communication capabilities, be it a smartphone, a camera on an oil rig, or an optical sensor on a steel mill, which collect and transmit data. It can be assumed that in a few years, technologies and systems based on the Internet of Things will be widely used in almost all manufacturing enterprises.

“Smart” sensors

Currently, 35% of manufacturers collect data from smart sensors and use it to optimize production and operational processes; 17% of respondents plan to do this in the next three years; another 24% of respondents said they have such plans, but the exact timeline has not yet been determined. Read more at industrial sensors marketplace SourceMe here.

About the Industrial Internet of Things

“Internet of Things” – concept interactions between devices, able to collect, store, process and send data to the internet directly to others. Devices can be the most different: from the camera sending images, before the sensor on the wind farm turbine collecting data on parameters environment and performance turbines. Sensors collect much data, including pressure data, humidity, optical indicators, speed moving parts, sound, etc.

For industrial enterprises “Internet things “becomes a whole ecosystem when thanks to software combined with cloud resources (or internal servers) and tools analysis, data streams become analytical information or forecasts, and with this information, you can familiarize yourself with a simple and a convenient interface (for example, in the form dashboards, mobile or WEB applications), allowing users to monitor and manage, and in some cases and automate management processes equipment or systems.

For incredible opportunities monitoring in real-time may be hiding the truth that not all manufacturers have the resources for large-scale data collection and management throughout the organization. In some cases, businesses don’t even experience this urgent need. If we talk about large international corporations, they invest huge funds in collection and processing systems data to drive growth productivity and quality improvement products, and sometimes even get the ability to track workers’ characteristics of these products after she leaves the workshop. Back in 2012, an American corporation General Electric (GE) announced that its investments in the implementation of the Industrial Internet “in production and service processes will amount to USD 1.5 billion. Under this program, the company, for example, installed at my factory in the city of Schenectady (state of New York), more than 10,000 sensors. These sensors connected to the internal LAN Ethernet and used for tracking material consumption, temperature control sintering used in batteries high-tech ceramics as well as atmospheric pressure. Through the factory Wi-Fi network data arriving directly to tablet devices workshop workers6 … One more example: in wind power plants GE has about 20,000 sensors, producing 400 measurements per second. Incoming data is analyzed almost in real-time, which allows you to optimize work turbines. The collected data stored and used for predictive analysts to improve the efficiency of technical maintenance and work to replace parts. But not all manufacturers can afford a program worth several billions of US dollars to master “Industrial Internet”.

Despite the limited financial and human resources, small and medium manufacturing enterprises too trying to find ways to succeed in an undertaking. Thanks to the renovation the refrigerator company reduced its costs by $ 250,000 per year. One of the most basic ways of application of the “Internet of Things” is the management of key EAM (Enterprise Asset Management). The emergence of technology cloud computing has led to decrease costs of computing resources for data processing and storage; hardware providing some devices too becomes cheaper. For example, the cost of micro accelerometers based on MEMS technology, formerly hundreds of dollars, now dropped to several tens of dollars. “Technology becomes much cheaper and easier to use, and therefore obstacles there are fewer and fewer for their implementation ”, – noted in her conversation with the representative PwC Betsy Page Sigman Sigman), professor emeritus, Lecturer at McDonough School of Business at Georgetown University. By to her, “in order to adjust sensors and configure, special knowledge is required “, but, having received them at your disposal, manufacturers of small and medium-size “can use funds warnings, alerts and data visualization and extract from this systems a huge amount of data. ” EAM systems are also used to solve less complex problems such as detection of energy losses. As an example can be considered a meat processing plant, on which the system was installed monitoring of electricity consumption, identifying causes over-expenditure of energy. In order to be able to collect data on electricity consumption through wireless LAN for subsequent analysis, the company modernized its machinery and equipment, as well as electricity meters.

Ultimately it turned out that one of the refrigeration units consumed much more energy than it should be. Receiving data on spending electricity in real-time, you can adjust the work schedule energy-intensive equipment at the plant in a way to avoid costs associated with peak load, and get a more accurate representation of the share of costs electricity at full cost products. “As soon as the manufacturer it becomes possible to get a detailed idea of the amount consumed electricity, it can keep track of costs for electricity and include them in full production cost “, – considers Arun Sinha, engineer and the head of the power supply department at Opto 22, which deals with the production of controllers for industrial automation, remote monitoring and collection data. “Previously, one of our customers (manufacturing enterprise) worked an employee who should take readings of shop meters electricity and record them in a special notebook, – said Arun Sinha. – We helped the client create a consumption monitoring system for electricity. The system was taking readings counters and sent data to the ERP system. Ultimately you, after all, you need to get detailed operational data and submit their board of directors in an easy to understand and easy to analyze. You would be surprised if you knew how much companies (including large ones) still adhere to traditional working methods ”. He also explained that manufacturers especially interested in gaining access to the operating data in the mode real-time via mobile remote applications monitoring systems and equipment (and in some cases for remote management).

Sensors are used not only to reduce costs. With their help, manufacturers are planning to ensure the quality of their products and even their safety. Consider as an example the pharmaceutical industry: optical sensors used here to measure optical properties within the framework of product quality control. The packaging is checked for compliance with the established rate of light transmission. it a big step forward compared to the used earlier by the method of verification by statistical sampling. Optical sensors are also used in difficult conditions, in particular in mines, on drilling rigs, in automatic welding machines, or in the steel industry 10. In the oil and gas industry sensors are used to measure certain indicators, for example, pressure, while they can transmit information to locking devices by closing or opening them, in order to prevent leaks11 … Despite the general increase in the level of use smart sensors, penetration of this technology production is still small. According to the results of our research, only 35% of manufacturers from the US collect and use data from smart sensors to improve the efficiency of their production and operational processes. Many are just starting to implement devices hoping to get more “situational awareness “about their activities. At the same time survey results also show that 24% do not plan to implement this technology, and another 24% have similar plans but did not set a specific time frame (see chart). The results obtained when answering the question of the more general use of any IP devices for increased interoperability in their production ecosystems, also were distributed among the “pioneers” and “bystanders”. Every fourth the manufacturer has already established an extensive network of IP devices, while 31% of respondents have no such plans. The remaining member’s surveys are in progress: 18% of them are starting for implementation, 26% have developed such plans.

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