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Introduction

In the era of Industry 4.0, industrial manufacturers can leverage remote monitoring tools to reduce production downtime and improve real-time operational visibility. Besides reduced downtime, real-time production monitoring can also improve asset utilization by 15-20%.

The emergence of technologies like the Industrial Internet of Things (IIoT) is adding a new dimension to the remote monitoring function. Manufacturers can now easily implement remote monitoring of both machines and processes.

IIoT-enabled remote monitoring goes beyond simply troubleshooting. Here are some of its other benefits:

  • Identifying and resolving production bottlenecks.
  • Improving production efficiency.
  • Improving business processes.

Through IoT-enabled remote monitoring, manufacturers can now monitor energy consumption and machine anomalies (in its initial phase). Through this blog, let’s take a closer look at how IIoT technology is transforming remote monitoring in industrial facilities.

What is Remote monitoring using IoT?

IoT-powered remote monitoring is essentially the application of IoT technology to remotely manage and monitor connected devices or systems. Using this application, OEMs can analyze data from IoT-connected sensors to extract real-time insights into device performance.

As the term indicates, remote monitoring enables OEMs to monitor their industrial assets and devices from any location and using any device. Besides manufacturing, IoT-enabled remote monitoring has applications in various industries including healthcare, agriculture, and technology.

Depending on the capabilities of the IIoT solution, companies can monitor various parameters including:

  • The temperature of the connected equipment
  • The air or steam pressure within the equipment
  • The current fill level of liquids within the equipment

Typically, an IoT-powered remote monitoring system has the following components:

  • IoT sensors collect real-time data from connected machines.
  • Connectivity tools transmit this data from the source to the target system.
  • An IoT platform collects and analyzes the transmitted data.
  • The user interface (UI) interprets and presents the data insights for easy consumption.

5 Benefits of IIoT-powered remote monitoring

With IIoT-powered remote monitoring, organizations can track, organize, and visualize their remote assets without physically being on the site. Among the benefits, IoT technology improves asset performance, minimizes resource consumption, and increases the lifeline of connected assets.

Here are 5 benefits of remote monitoring tools enabled by IoT technology:

1. Lower maintenance costs

Industrial companies lose around 23 hours of production time every month due to machine failures. This comes at a heavy cost of $187,500 every hour. With IIoT-connected sensors, companies can replace scheduled maintenance operations with data-driven predictive maintenance.

By detecting machine anomalies early, remote monitoring tools reduce repair costs and improve productivity.

2. Reduced operating costs

Besides maintenance, IoT-enabled remote monitoring systems can reduce operating costs by monitoring and reordering essential raw materials and machine components. Effectively, it ensures that no machine has a faulty component, while production does not run out of inventory items. Hence, manufacturers can reduce their inventory costs and efficiency.

3. Centralized monitoring

Remote monitoring is an asset for manufacturers operating across distributed locations. Cloud-enabled IIoT remote monitoring enables them to access real-time data from remote sites – at any time, from any location, and on any device. With centralized IoT platforms, companies can collect and analyze the current health and performance of all their assets on the same platform.

4.  Sustainability

In the current climate-conscious business environment, manufacturers must adhere to sustainability practices to reduce their energy consumption. The industrial sector accounts for around 54% of the global energy consumption. With growing consumption, energy waste is also on the rise in recent years.

IoT-enabled remote monitoring can boost sustainability goals by exposing the root cause of wasted energy. IoT technology can also accurately predict future energy demands and accordingly optimize energy consumption across the facility.

5. Productivity tracking

With IoT-enabled remote monitoring, organizations can now remotely track their production facilities for productivity. For instance, they can track OEE (Overall Equipment Effectiveness) which measures productivity in terms of equipment downtime, production rate, and process quality.

Additionally, manufacturers can track production-related KPIs such as:

  • Overall line efficiency (OLE)
  • Quality metrics
  • Equipment uptime and idle time

How to enable remote monitoring using ThingWorx

As an Industrial IoT platform, ThingWorx can help manufacturers realize the full potential of remote monitoring. Here are some of the capabilities of this industry-recognized IIoT platform:

  • Standardizes industrial connectivity over disparate devices and applications, thus enabling remote access to multiple data sources.
  • Leverages the features of its in-built accelerators to implement and scale IIoT solutions.
  • Extracts valuable real-time insights from IoT data to optimize operations and reduce costs.
  • Provides end-to-end control and visibility over IoT-connected devices and processes, thus boosting performance.
  • Enables safer effective ways for employees to interact with physical systems.

Here’s an illustration of how Pratiti Tech implemented an IoT-powered CNC monitoring solution to display OEE and OLE measurements:

Using real-time production monitoring, Pratiti’s IIoT solution delivered the following results:

  • 30% reduction in product rejections and reworks.
  • 15-20% improvement in asset utilization
  • 30% more control over each processing unit in shop floors

Conclusion

In recent years, IoT technology has emerged among the primary drivers of digital transformation across industries. By enabling remote monitoring, Industrial IoT can save operational costs and improve machine uptime from remote locations.

Among the leading IoT solution providers in India, Pratiti Technologies offers a host of customer services in the IoT domain including consultancy, development & testing, design, and operations. Our knack of building custom applications leveraging IIoT platform is being used in the manufacturing industry for the following use cases:

  • Predictive maintenance
  • Inventory management
  • Quality control
  • Connected factories

With our IIoT accelerator, you can design your next digital transformation initiative on time and with efficiency. Do you want to know more? Contact us today!

Nitin
Nitin Tappe

After successful stint in a corporate role, Nitin is back to what he enjoys most – conceptualizing new software solutions to solve business problems. Nitin is a postgraduate from IIT, Mumbai, India and in his 24 years of career, has played key roles in building a desktop as well as enterprise solutions right from idealization to launch which are adopted by many Fortune 500 companies. As a Founder member of Pratiti Technologies, he is committed to applying his management learning as well as the passion for building new solutions to realize your innovation with certainty.

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