Whether you call it Manufacturing 4.0 or simply the continued march toward improved productivity since Ford’s moving assembly line in the early 1900s, the drive for efficiency, oversight, and cost reductions are top of the list for manufacturers around the world. Robotics have certainly played a big role in advancing automation and consistent performance, but IoT has also risen to the top of the technology stack and is helping drive greater levels of distributed monitoring and management on a huge scale. For ISVs and solution developers working on enhancing factory automation, the application of AI and advanced IoT in manufacturing, and addressing global regulatory challenges, is ripe for innovation.
Control Network Capacities
While groundbreaking, Ford’s ideas have given way to demand-driven concepts such as the Just in Time (JIT) approach in the 1970s, and advances in automation-enabled enhanced remote communication technologies linking control rooms to systems through local telematics networks. In today’s factory, there is an immediate demand for real-time information to support not just faster performance on the production line, but the ability to push intelligent decision making closer to the edge of the network without sacrificing oversight and control.
IoT – or more specifically, Industrial IoT – emerged from the telematics world as a better and higher-capacity way to connect endpoints to control centers, initially through SCADA systems carrying Modbus and other machine protocols. Current day IoT networks have the capacity and reliability to carry high-definition video that enables real-time remote monitoring, control, and quality management. It is already being applied in AI use cases to speed production. In addition, the use of wireless networks for these connections provides a foundation for flexible factory innovation which can offer advantages for demand-driven manufacturing, as well as streamlined retooling and adaptation to supply chain disruptions.
Resilient Connections Where and When Needed
For distributed, and even multinational manufacturers, IoT and wireless connectivity dramatically expands the potential automation landscape, enabling flexibility, efficiency, and improved access to management and control capabilities. With nearly ubiquitous cellular network coverage that is supplemented by satellite in remote areas, global IoT networks provide reliable connectivity to factory management platforms and independent systems from anywhere in the world. These networks not only support substantial data transfer volume for logging and performance monitoring, some networks offer sub-250msec round-trip latency, expediting alert responses and mitigation efforts on the manufacturing line.
Connecting georedundant management centers or simply providing resilient connections to the factory control center from a mobile platform is a straightforward technology concept. However, the business side of activating and managing cellular IoT connections in different countries and global regions can be onerous and costly, both in performance and financially. Most mobile operators are attuned to personal cellphone use models that rely on roaming agreements, and there is a general tolerance for occasional dropped calls or variable signal strength. These parameters are not acceptable for automated factory controls. To maintain proper operational control, there should be resilient multi-carrier connections at all sites and endpoints that do not rely on roaming agreements. Roaming seldom includes the same service level agreement (SLA) guarantees as a local provider contract.
Top-tier global IoT network providers will support connections to local providers in the desired regions using intelligent SIMs that support multiple mobile services. These systems should also include cellular network performance monitoring and support automated switching to ensure resilient and consistent connectivity. IoT connectivity solutions providers will also manage the necessity of maintaining contracts and SLAs with mobile network operators, streamlining direct cost management and eliminating back-office labor costs for the manufacturer.
Local and Global Regulations
IoT service providers are also highly attuned to the nuances of local and global regulations that can impinge on the business side of manufacturing. From countries and regions that place restrictions on roaming duration to data sovereignty and privacy mandates, compliance can be a confusing and potentially costly web if not managed properly. On balance, it is likely that the IoT provider will alleviate the risk of compliance missteps and reduce back-office resource demands for the manufacturer.
Design and Implementation of Global Factory Automation
The automation landscape is rapidly evolving to adapt to shifting supply and demand, global trade and regulatory challenges, and constant demand for cost reduction coupled with increased output. In updating or designing factory automation products and systems, modern IoT connectivity provides an excellent foundation for reliable and flexible operational control in local, regional, and global settings. Partnering with a top-tier IoT connectivity provider should deliver the best outcomes for both current and future projects.
