Manufacturers are predicted to lose $50 billion a year due to unexpected interruptions, but many plants continue to use outdated procedures that provide limited real-time information. 

This is where IoT in industrial automation is pivotal.

Companies may remotely monitor processes, identify problems promptly, and achieve unprecedented production efficiency by incorporating industrial IoT automation. 

Automation and IoT are turning manufacturing into a data-driven powerhouse with features like real-time analytics and predictive maintenance.

However, what is the real mechanism of this technology? Could IoT be used in industrial automation to eradicate inefficiencies? 

In order to help you comprehend why smart factories are the way of the future, this blog will examine the application of IoT in industrial automation. Additionally, it will discuss important challenges of industrial IoT automation, and present real-world examples. 

Let's get started with industrial automation and IoT.

To better understand how IoT in Industrial automation is revolutionizing the industry, we need to understand the connection between the two. Let's start with a simple one. 

What Is Industrial Automation? 

Industrial automation is the application of various control systems (computers and IT) for managing different processes and machinery in industries to replace human involvement. Essentially, it's the use of technology to perform tasks that would otherwise require human labor. 

Industrial automation is implemented using various technologies. This includes programmable logic controllers (PLCs), industrial PCs, SCADA systems, and, more recently, the IoT.

The role of IoT in industrial automation is altering how industries operate. IoT automation enables factories' systems, machines, and gadgets to connect with one another and optimize operations in real time. 

The extensive adoption of industrial automation in IoT helps improve decision-making, minimize downtime, and increase operational effectiveness.

Consider, industrial IoT devices examples: IoT provides predictive maintenance, which helps to avert expensive breakdowns before they happen, thanks to sensors installed in machines.

The power of automation in IoT lies in its capacity to collect and process massive volumes of data from networked devices. This enables enterprises to automate complicated procedures and make adjustments in real time without requiring human involvement.

IoT automation thereby aids companies in streamlining their processes while also achieving increased accuracy, reduced expenses, and increased production.

How IoT Plays a Part in Industrial Automation?

So, you know how we're increasingly using devices that talk to each other in our daily lives, right? 

Like how your smartphone can tell your home thermostat to adjust the temperature when you're heading back home. Well, this is IoT in action, where devices are connected via the internet to share and use data to perform tasks. 

Now, imagine that concept on a much larger industrial scale. In an industrial setting, machines, sensors, and humans can all be interconnected, exchanging data and making decisions in real time. This is where IoT truly shines in the realm of industrial automation. 

For instance, a sensor detects that a machine part is overheating on a production line. The sensor, being part of the IoT system, immediately communicates this information. The system can then automatically adjust the machine's operation to prevent damage. Or alert a human operator to take action. 

How does IoT increase productivity?

Real-Time Data Collection

IoT devices, such as sensors and smart machines, can collect vast amounts of data in real time from various points in an industrial process. 

Data Analysis and Insights

The data collected by IoT devices is sent to a central system, where it's analyzed to derive meaningful insights. Advanced analytics and machine learning algorithms can identify patterns, trends, and anomalies. This is further used to optimize processes, predict equipment failures, or identify bottlenecks in production. 

Process Automation and Optimization

The insights derived from data analysis can be used to optimize industrial processes automatically. For example, suppose a sensor detects a drop in the efficiency of a machine. It could trigger an automatic response to address the issue, such as adjusting the machine's parameters or scheduling it for maintenance. 

Monitoring and Control 

IoT in industrial automation allows for remote monitoring and control of machinery and processes. This means that operators can oversee operations from anywhere in the world, using devices connected to the internet. This enhances flexibility and allows for quick responses to any issues. 

Predictive Maintenance

IoT can predict potential equipment failures by continuously monitoring the condition and performance of machinery. This leads to cost savings by allowing for planned maintenance, avoiding unexpected downtime, and extending the life of the equipment. Read on to learn more about predictive maintenance. 

Now that we have understood the connection between IoT and industrial automation, let’s discuss some of its applications.

Industrial automation using IoT has applications in various industries, leading to more efficient and productive industrial automation processes. Let's dive into some specific industrial IoT devices examples across industries: 

1. Manufacturing

A significant application of IoT in manufacturing is in quality control and assurance. In the past, quality control often involved manual inspection, which could be time-consuming, costly, and prone to human error. 

However, IoT is revolutionizing this manufacturing area by enabling real-time, automated quality control. One example is Siemens' implementation of IoT in its electronics manufacturing plants. 

The company has equipped its production lines with a network of IoT sensors to monitor their process in real time. These sensors can collect various data, including temperature, pressure, vibration, and visual information. 

The collected data is then analyzed to detect deviations from the standard parameters that may indicate a quality issue. As a result, it helps reduce waste and ensure high quality and consistency in final products. 

Also, take a look at this manufacturer’s guide to scaling Industrial IoT.  

2. Agriculture

IoT is revolutionizing agriculture through precision farming. Sensors can be used to monitor various factors such as soil moisture levels, crop growth, and livestock health.

For example, John Deere, a leading agricultural machinery maker, has tractors equipped with IoT sensors and GPS. This is to provide farmers with precise data on crop health and weather conditions, thereby reducing waste and increasing yield.

3. Logistics and Supply Chain

Logistics is another field where IoT is making a significant impact. Take the example of DHL's SmartTrucks. They equipped their vehicles with IoT devices to track real-time to collect data like traffic conditions and delivery schedules. 

In doing so, they were able to optimize the route planning and reduce fuel consumption and delivery time. The end result contributed to both efficiency and sustainability. 

Learn more about how IoT is transforming supply chain management. 

4. Energy 

IoT in the energy sector plays a pivotal role in creating smart grids. A good example of this is Italy's Enel. The company has deployed over 30 million smart meters to monitor and optimize energy consumption. 

The result? 

Consumers could better understand their energy usage, while Enel could predict demand, manage supply efficiently, and quickly detect any faults in the system. 

5. Automotive

IoT is transforming automotive manufacturing and post-production services. Tesla, for instance, uses IoT for its vehicle production lines to monitor and optimize processes. They also use IoT in their electric vehicles to provide remote diagnostics, predictive maintenance, and over-the-air software updates. 

The development of electric vehicles is an intricate process. Manufacturers are finding it hard to find a smooth process as they had for ICE engines. Digital twins are helping them here. It's the future of manufacturing and uses IoT. 

Follow the link to learn more about the usage of digital twins in electric vehicles. 

6. Healthcare

IoT in healthcare brings about remote patient monitoring, smart sensors, and wearable devices. This enables personalized care and early detection of potential health issues. 

An example is Proteus Digital Health's ingestible sensors. When swallowed with medication, these sensors send data to healthcare providers about patients' medication adherence. This allows for real-time adjustment of treatment plans and better patient outcomes.

Now that we have understood the applications of IoT in Industrial Automation, let's see the impact IoT has on industrial automation. 

IoT is radically reshaping the landscape of industrial automation, creating opportunities for enhanced efficiency, productivity, and flexibility. Simultaneously, it also presents some challenges that need to be navigated carefully.

Advantages of IoT in Industrial Automation 

Enhanced Efficiency and Productivity 

IoT in automation helps optimize various industrial processes by enabling real-time monitoring and data analysis. This leads to increased productivity and efficiency. 

Improved Quality Control 

Automation in IoT allows for detailed tracking and analysis of production processes. This ensures high-quality output and reduces the rate of defects and wastage. 

Increased Safety 

By monitoring environmental conditions and detecting hazards, IoT enhances workplace safety. Protecting both employees and assets. For more about this, read how cloud-based IoT can enhance security. 

Better Decision-Making 

IoT devices offer data-driven insights that can be helpful in strategic decision-making. Doing so allows businesses to be more agile and responsive to the changes in the market. 

Real-Time Control and Monitoring

IoT-based automation makes it possible to monitor and make changes instantly by providing real-time data from systems and machines. This helps avoid expensive downtime and maintains processes operating seamlessly.

Predictive Maintenance

The capacity of IoT automation to foresee equipment failures is one of its most significant advantages. Businesses can minimize downtime by scheduling maintenance before problems worsen by evaluating sensor data.

Cost Reduction

IoT contributes to minimize operating expenses by automating procedures and decreasing equipment downtime. Additionally, it lessens the need for manual supervision, freeing up staff members for more strategically important duties.

Remote Access and Management

The automation of IoT enables autonomous control and oversight. This offers greater adaptability and surveillance, and is especially helpful in businesses where managing many sites or locations is crucial.

Challenges of IoT in Industrial Automation

Data Security and Privacy

Interconnectivity is the sole in IoT devices, which means that the data collected is transferred from one device to another. This could raise concerns about data privacy and security. Industrial systems are more prone to cyberattacks. Therefore would require robust security measures in place to protect their data. 

Interoperability

With numerous IoT devices and platforms available, ensuring they can communicate and work together seamlessly can be challenging. 

Data Overload

There are a lot of devices interconnected, collecting and passing data in an IoT environment. The volume of the generated data will be vast, and managing it can be daunting. Companies need to have robust data management and analysis systems in place to make the most of this data. 

Cost and Complexity of Implementation

Implementing IoT in industrial automation can be costly and complex, particularly for SMEs. It requires a significant investment in new equipment and possibly staff training. They might even have to hire more experienced employees, which may be beyond the reach of some companies. 

While IoT is offering considerable benefits, it's essential to understand and navigate these challenges. By doing so, they can fully harness the potential of IoT to drive their growth and success in the digital age.

As we look toward the future, it's clear that the IoT and automation will continue to be a significant player in industrial automation. Here's a peek into what's on the horizon: 

1. Artificial Intelligence and Machine Learning Integration

As data becomes the new oil, using AI and machine learning in conjunction with IoT will further enhance automation capabilities. This pairing can lead to more advanced data analysis, better decision-making, and even autonomous machinery. 

2. Rise of Digital Twins

A digital twin is a virtual model of a physical object or system. Coupled with IoT, digital twins will become more prevalent, allowing for more accurate simulation and analysis of industrial processes. 

This technology can improve product design, optimize manufacturing processes, and reduce machinery downtime. Learn more about the use cases of digital twins. 

3. 5G and IoT

The rollout of 5G networks will dramatically improve the connectivity of IoT devices. This enables faster data transmission, more reliable connections, and the ability to connect more devices. This will pave the way for more complex and powerful IoT networks in industrial settings.

4. Edge Computing

With the growing volume of data generated by IoT devices, edge computing will become increasingly important. 

If you don't know - Edge computing is basically processing data closer to where it's generated, at the "edge" of the network. 

This shift can reduce latency, conserve network bandwidth, and improve data security. All these are critical factors in many industrial scenarios. 

5. Greater Emphasis on Cybersecurity 

The need for robust cybersecurity measures will intensify as reliance on IoT grows. We can expect advancements in IoT device security and the development of more sophisticated strategies to protect against cyber threats. 

6. Sustainability and Energy Efficiency 

With growing concerns about environmental sustainability, IoT will play a key role in enabling more energy-efficient industrial operations. IoT devices can monitor and optimize energy usage, helping industries to reduce their carbon footprint. 

Suggested Read: Green IoT for Businesses.

The future of IoT in industrial automation is brimming with exciting possibilities. As technology evolves, the synergy between IoT and industrial automation will become increasingly powerful. This can lead to a more connected, efficient, and sustainable industrial landscape. 

Embracing these trends will be key for businesses aiming to stay competitive in the Industry 4.0 era.

IoT in industrial automation has sparked a transformative shift in how industries operate. Businesses are now experiencing remarkable boosts in both efficiency and productivity. And not to mention how streamlined the decision-making process and operation monitoring have become. 

As more companies adopt IoT, we can expect greater automation and enhanced customer experiences. It has become imperative for businesses to leverage these advanced technologies if they are to stay ahead of the curve in the Industry 4.0 era. 

So train your existing crew, hire experienced personnel, or outsource the development. Partnering with tech experts can save time, money, and resources. Companies can focus on the things that matter while the partners ensure the quality development of the product. 

If you are looking for such partners, Toobler will be a great choice. They have dedicated teams with good command over the latest cutting-edge technologies like IoT, AI, and Digital twins. Take a look at their digital transformation solutions and see how they can help get a competitive edge. 

An IoT case study on industrial automation demonstrates how automation and IoT can transform manufacturing by converting reactive to proactive maintenance, which saves resources, time, and money.

Refer to our case studies: https://www.toobler.com/casestudy 

Contact the experts at Toobler and build your digital future together.

1. What makes an IoT in an industrial automation system?

IoT sensors and devices, networking options, data analytics software, cloud or edge computing platforms, and control and monitoring user interfaces are some of the essential elements.

2. Is it possible to incorporate IoT in industrial automation with existing systems?

Yes. It is possible to incorporate IoT industrial automation with current industrial systems. In order to facilitate effortless interaction between both traditional and modern technologies, this integration entails linking legacy equipment with Internet of Things devices and utilizing middleware.

3. What challenges does IoT in industrial automation face?

The various challenges of IoT in industrial automation are:

• Data Security and Privacy

• Interoperability

• Data Overload

• Cost 

• Complexity of Implementation

4. What is the role of IoT in the automotive industry?

The way automobiles are made, maintained, and driven is being revolutionized by the Internet of Things. The following is the impact of IoT in the automotive industry:

• Connected Vehicles

• Predictive Maintenance

• Smart Manufacturing

• Fleet Management

• Enhanced In-Car Experience