Indian manufacturers adopting IoT and Industry 4.0 solutions isn’t just a trend but a necessity to stay competitive in the global market.
The NASSCOM report projects that digital technologies will account for 40% of India’s total manufacturing expenditure by 2025, up from 20% in 2021. This new wave of innovation in the manufacturing sector is changing the way products are made, bringing smart technologies like IoT, AI and automation into the mix.
This blog tells you everything about essential Industry 4.0 solutions that Indian manufacturers need to consider and how they help them stay ahead of the curve.
A gist about Industry 4.0 solutions
Previously, we had three different industrial revolutions and Industry 4.0 is the fourth one, also called the fourth industrial revolution. This started gaining traction only in 2011, aiming to use high technology to boost innovation in manufacturing.
So, Industry 4.0 is all about machines connecting and communicating with each other, making smart decisions and working smart.
This revolution has spread globally, reshaping industries and setting a new benchmark for the manufacturing sector.
Key IoT and Industry 4.0 solutions for manufacturers
Below, you will find the IoT and Industry 4.0 solutions tailor-made to enhance manufacturers technology:
1. Big Data and Analytics in Manufacturing
These technologies provide the necessary insights to make smarter and faster decisions in manufacturing.
When all machines are connected together in a factory, we get tons of data from them in real-time. But if we lack the right tools to analyze and extract insights, this data is just noise.
So, with Big Data, we can collect the necessary data and store it efficiently. With analytics, we can predict future trends and optimize the factory’s manufacturing processes.
2. Cybersecurity solutions
When your factory gets connected to the internet, it’s naturally prone to cyberattacks.
A single system can become an entry point for an attack and other systems can easily fall prey. This is why implementing robust and intelligent security solutions to handle data breaches and attacks is important to make sure your system is secure. If any attack occurs, the particular part will be segregated and cleaned up without bringing the entire system down.
3. Artificial intelligence and manufacturing
Artificial intelligence (AI) is revolutionizing industrial IoT by leaps and bounds. It makes operations run faster, more efficient and more automated.
It’s already being used to predict industrial market trends, optimize supply and demand and perform preventive maintenance. So, with the rapid growth of AI, it will prepare the machines in the factory to spot and solve inefficiencies on their own with the help of Big Data and Machine Learning.
4. Autonomous robotics
Though robots lack human-like intelligence and abilities, we must accept that manufacturing automation has advanced a lot over the years. Robots are already being used widely in factories to handle repetitive tasks.
So, in manufacturing, robots are used in:
- Continuous production as they can work around the clock
- Can handle dangerous tasks
- With other technologies embedded, they can make quick and independent decisions
- Some of the latest robots have such advanced capabilities that they don’t need any human intervention.
5. Simultations and Digital Twins
The Digital Twins technology is a virtual replica of real-world objects. In our case, in the manufacturing sector, we can use this technology to replicate machines or even entire factories.
So manufacturers can imagine different scenarios for how a machine would work or handle specific situations without actually investing in one and taking a risk.
Digital Twins are great for training employees, as they can learn and practice how to operate equipment or handle specific situations in a virtual environment.
6. Additive Manufacturing
This is just a fancy industrial term for 3D printing. Instead of the traditional manufacturing method of cutting or shaping material, 3D printing is used to create objects of your preference.
You can simply design a model using computer-aided design (CAD) software or even scan an existing object with a 3D scanner. Update the digital blueprint, add materials to the 3D printer and you get the result. It’s that simple.
7. Industrial IIoT (IoT)
As for the manufacturing sector, IIoT comes with device sensors that collect operational and environmental data in a factory. The data collected from these sensors influences other manufacturing processes and technology decisions.
Besides incorporating this technology into manufacturing equipment, it can also be used for other systems such as air filtering, HVAC, etc.
What are the benefits of implementing Industry 4.0 solutions?
Quicker product rollout
With increased automation, there is no room for errors, and there is lower production variability and increased work visibility. The best thing is that you can monitor everything in real-time. This lets manufacturers speed up how quickly they can bring products and services to market.
Thanks to Industry 4.0 technology, manufacturers can have real-time data into every aspect of their operations. So, if any issue pops up, it can be fixed easily.
This shift from old-school paperwork or manual work to instant data capture and automation helps your manufacturing business flourish.
Increased efficiency and productivity
One of the biggest pros of having IIoT applications is that it makes it easy for companies to do more with less. We all know that the manufacturing sector mostly entails repetitive tasks. When this is automated, efficiency and productivity increase automatically.
Also, these advanced technologies, like Machine Learning, Big Data and Analytics keep an eye on the entire manufacturing process in real-time. So, it makes it easy for them to catch problems and solve them quickly. This way, there is no downtime and production goes smoothly.
The integration of advanced technologies boosts process efficiency and reduces unplanned downtime. This way, there’s significant growth in India’s industrial automation market, which is projected to grow at 14.26%, reaching $29.43 billion by FY2029.
Improved worker safety and working conditions
IoT-enabled wearable and augmented reality (AR) tools help improve worker safety and working conditions by providing real-time information and support.
Collaborative robots, also known as cobots, work alongside human workers, specifically performing demanding or dangerous tasks. This not only increases the safe environment for workers but also lets them focus on more complex, value-added activities.
Saves your pocket
You may argue that incorporating IIoT into your manufacturing factory is expensive. But see this as an investment that saves you a ton in the long term. It also eliminates downtime, improves energy efficiency, etc.
For example, when these technologies predict any potential failures before they happen, manufacturers can schedule maintenance during non-peak times. This way, you can prevent costly breakdowns and extend the life of machinery.
Common barriers faced by Indian manufacturers in adopting IIoT solutions with solutions.
Limited infrastructure and connectivity
Though India is scoring well in terms of technological advancement, it still has a long way to go. One of the primary issues with the adoption of IIoT is limited infrastructure and internet connectivity. Even adding IoT devices to factories with existing infrastructure poses challenges in major cities.
Though the two-tier and three-tier are advancing, they’re not ready completely. Even today, we can find rural areas struggling to get stable networks.
To solve this issue, we recommend taking advantage of government programs aimed at improving digital infrastructure. Our government has come up with multiple initiatives focused on digitalizing India.
Security concerns
When there are a vast number of devices connected to the internet, the possibility for cyberattacks peaks. What if someone else is eavesdropping? Promising robust security across all devices and networks becomes a major challenge.
By investing in cybersecurity solutions and regularly updating them, you can safeguard your system from potential cyber attacks.
Compatibility issues
We know that the existing traditional systems were not designed with IoT in mind. As for some factories, the cost and effort that’s required to bring existing systems up to speed with IoT capabilities may not be possible.
Consider deploying IoT gateways or middleware that can act as a bridge between older systems and new IoT devices. Industry 4.0 solution providers can help you in this matter.
Cost of upgrades
Even if you are ready to upgrade your existing system to fit in, the associated cost can be expensive. If you are starting over, the initial investment required for IoT adoption is high. Here, you must also consider maintenance and the regular updates that will come in the future.
It’s better to seek financial assistance and take advantage of government grants and subsidies. Or, you can implement cost-efficient technologies and plan for long-term savings.
What are the steps to implementing Industry 4.0 in your factory?
Here’s a quick guide to get started with Industry 4.0:
Assess your current setup
Evaluate your existing machinery setup, processes and technology. Identify areas that could benefit from automation, IoT, or AI and other advanced technologies.
Set clear goals
List the problems that your manufacturing factory is currently facing, be it downtime, improving product quality or wanting to cut costs. Either way, set clear goals.
Invest in the right technology
This is an important step. You must choose technologies that align with your goals. For this, you must hire the right Industry 4.0 solution provider in India.
Build a team
Though you will hire an Industry 4.0 solution provider to incorporate such technologies in your factory, you must train your workforce so that they become comfortable working with new technologies.
Collaborate with potential people
Work with technology providers, consultants and industry experts who can offer guidance and support.
Monitor and adapt
Continuously monitor your progress; only then will you know whether you are profiting and going in the right direction.
Final Words
IoT and Industry 4.0 solutions have the power to change your manufacturing factory into a smarter and more efficient one because these technologies are revolutionary. But you must hire the right industry 4.0 solution provider to get started, right?
Feeling stuck and planning to adopt or upgrade your manufacturing factory setup?
Are you looking to get help from Industry 4.0 experts? Get in touch with Sterison, one of the leading industry 4.0 solution providers in India. Call us now and let’s figure out how to scale your business.
