The industrial Internet of Things (IIoT) is revolutionizing manufacturing operations by connecting machinery and devices at smart factories and other industrial sites, where equipment operational efficiency is crucial for productivity and safety. 

IIoT technology enables companies to automate previously manual processes and manage their assets remotely, resulting in new efficiencies and cost savings. According to a recent Future Market Insights report, the global industrial IoT market is expected to grow from $323 billion in 2021 to $1.3 trillion by 2032 at a CAGR of 12.2%.

In this article, we will explore the following five Industrial IoT applications:

• Asset tracking: GPS-enabled devices can track assets on the move, from vehicles to individual crates and boxes.
• Proactive maintenance: Connected sensors help predict needed maintenance for industrial machinery and other assets.
• Enhanced inventory management: IIoT devices are bringing increased visibility to supply chains and inventory for companies in the industrial sector.
• Remote monitoring and control: IoT sensors can perform some elements of assembly line inspectors’ role by checking machinery for performance issues or defects and alerting managers when there’s a problem.
• Employee and environmental safety: Companies are using connected sensors to help monitor equipment usage, site logistics, and worker safety, making regulatory compliance a simpler task.

What are the benefits of Industrial IoT

IIoT offers numerous benefits across various sectors. It optimizes and automates operational processes using technologies like big data analytics, robotics, AI/ML, and 5G. By connecting machines to intelligent software through sensors, IIoT enhances performance monitoring and automation.

IIoT reduces errors by digitizing operations and minimizing manual processes, leading to improved control and reduced errors in manufacturing. Additionally, it applies data-driven insights to operations, monitoring, and marketing processes, reducing costs and enhancing revenue.

Overall, IIoT provides remote monitoring, predictive maintenance, improved workflows, and enhanced decision-making, leading to increased efficiency and improved product quality. It also drives productivity, efficiency, and profitability across industries.

5 Industrial IoT Applications and Use Cases

An overwhelming 92% of industrial organizations have embraced IoT solutions to enhance their monitoring, maintenance, and remote operations. This article delves into five key applications of Industrial Internet of Things (IIoT) technology.

Asset Tracking

Through the use of GPS technology and sensors, organizations can monitor and manage their assets, whether stationary or in transit. Cellular IoT sensors, unlike traditional radio frequency identification tags, provide continuous updates, enabling managers to track assets’ progress in real time.

For instance, rental companies can leverage GPS-enabled IoT devices to gain real-time insights into the location and condition of their assets in the field. This data can be utilized to enhance logistics planning and customer service by streamlining pickups and returns.

Proactive Maintenance with IoT

In the past, proactive maintenance involved periodic in-person servicing of machinery. However, the integration of cellular IoT has introduced new possibilities. For example, instead of dispatching human mechanics for time-based service, managers can now remotely monitor machines using IoT sensors.

These sensors track crucial performance metrics in real time and send alerts when issues are detected, transforming proactive maintenance into a nimble and responsive process.

The resulting decrease in service calls can enhance operational efficiency, lower operating costs, and save significant time, effort, and money when monitoring remote assets. This is particularly important considering that, on average, 31% of a company’s assets are in the field today.

Enhanced Inventory Management

Visibility is crucial in inventory management, as lack of insight can lead to inefficiencies and significant financial losses. Fortunately, recent technological advancements have enabled increased visibility through connected IIoT solutions.

Nowadays, small 4G-connected microcontrollers can identify, locate, and monitor moving assets in real time from almost anywhere in the world. Additionally, more advanced and affordable IoT platforms facilitate data reception, organization, and analysis via the cloud.

Automated alerts and event reporting enable companies to be agile and responsive in addressing supply chain and inventory disruptions. IoT sensors provide real-time insights, allowing organizations to maintain necessary consumables (e.g., fuels and lubricants) to minimize downtime. The capability to track the condition of specific components empowers companies and their customers to order replacements in advance.

Remote Monitoring and Control

Remote monitoring and control are key capabilities provided by the Industrial Internet of Things (IIoT). These capabilities allow for the visualization, tracking, and control of assets and facilities without the need for on-site presence. IIoT sensors can provide constant updates on the geolocation and mechanical status of industrial machinery, and they also offer the ability to remotely change settings, activate equipment, or halt processes when necessary. 

For instance, if a water pump breaks and starts to leak, an alert can be received and shutdown protocols can be engaged right from a device, regardless of location. This functionality is particularly useful for assets located in hard-to-reach areas, as sending a technician to a distant location can be expensive and time-consuming, especially when the only action needed is a simple settings tweak or standard reboot.

In manufacturing applications, remote monitoring connections are typically linked to programmable logic controllers (PLCs). This gives managers remote access to reports and other logged data, along with the ability to send commands directly to machines or deliver instructions to a facility’s human operators

The benefits of remote monitoring using IIoT include centralized monitoring, accurate monitoring, and improved profitability. Centralized monitoring allows for access to asset information from anywhere, anytime, and on any device, even if the assets are in different physical locations.

3 Examples of Industrial IoT Applications in Action

1. Tesla

Tesla is reinventing lean manufacturing by incorporating Industrial IoT technology into its operations. The company’s strategy involves treating the factory as a product rather than a place, and solving manufacturing issues by drawing from diverse technical and engineering backgrounds.

In Tesla’s Gigafactory, Autonomous Indoor Vehicles (AIVs) are used to improve material transfer between workstations, operating based on complex logic algorithms without requiring preset paths.

2. Caterpillar

Caterpillar has embraced Industrial IoT by equipping its machinery with intelligent sensors and network capabilities, leading to the deployment of their digital solution, Cat Connect Technologies and Services, on over half a million Caterpillar vehicles. This solution collects and analyzes usage data to optimize equipment management, safety, sustainability, and productivity, enabling users to create predictive maintenance solutions and discover new ways to enhance efficiency. 

The application of this solution across various industries has yielded significant benefits, such as a company using Caterpillar’s marine equipment, which increased the longevity of their generators and saved $650,000 annually through predictive maintenance analysis using power output data. Caterpillar’s commitment to Industrial IoT reflects its dedication to leveraging technology to drive operational excellence and deliver value to its customers.

Hortilux

Hortilux, a prominent provider of high-quality lighting solutions for commercial growers, is revolutionizing the horticultural tech industry with a solution that grants growers enhanced control over the quality of their harvests. Similar to Caterpillar, Hortilux empowers customers to make informed decisions through precise and robust data analysis. 

Their equipment is equipped with cloud-enabled smart sensors that connect commercial growers to HortiSense, a software solution offering comprehensive visibility of growing operations. HortiSense analyzes growing conditions, including weather forecasts and energy rates, to inform the grower’s lighting strategy, enabling the development of a lighting strategy that maximizes crop quality while minimizing energy consumption. This results in increased yield and cost savings, demonstrating a mutually beneficial outcome for growers. 

To explore more examples of Industrial IoT in action, click here.

Final Thoughts

The Industrial Internet of Things (IIoT) is revolutionizing manufacturing operations by connecting machinery and devices at smart factories and industrial sites, where equipment operational efficiency is crucial for productivity and safety. This technology enables companies to automate previously manual processes and manage their assets remotely, resulting in new efficiencies and cost savings.