Revolutionizing manufacturing by eliminating downtime and ensuring safety

Unplanned downtimes in manufacturing may lead to tremendous financial losses and disrupt an organization's workflow. However, utilizing the Internet of Things (IoT) can aid businesses in mitigating manufacturing downtimes via various methods. Adopting this technology necessitates investments in time and money, but the resultant positive consequences are frequently valuable.

The crippling effects of downtime

Often overlooked is that the consequences of machine downtime extend far beyond the single machine experiencing the issue. The most apparent initial effect might be that the company cannot utilize specific equipment. However, the total duration of the outage could increase if the company has to wait for a part to be specially ordered or if the maintenance technician takes longer than expected to diagnose and offer a solution. Additionally, depending on the purpose of the machine, the company may need to completely restructure its production process or temporarily shut down a portion of the factory due to the outage.

In some cases, the outage could impede the company's productivity, limiting the number of employees working during a specific shift. If the machine failure impacts a tight deadline, the company risks disappointing its customers or failing to fulfill an associated contract.

Manufacturers have a range of options available to them for minimizing downtime with IoT. One of the most popular solutions is applying technology for predictive maintenance. According to research, this approach could lead to a 70-75% reduction in equipment breakdowns and a 35-45% decrease in downtime.

As a starting point, the IoT can reduce the frequency of machine failures. When failures do occur, the duration of the equipment's inability to function should be minimized. These effects should lead to less overall disruption and provide companies with greater flexibility in handling such occurrences.

How IoT reduces manufacturing downtimes

Reducing manufacturing downtime is a top priority for the industry, as it can result in high costs and lost productivity. However, some parts replacements can take longer than expected, especially when dealing with machinery that operates at high temperatures. Cooling such equipment down before replacing a part can be a time-consuming process, so it is crucial to plan maintenance or parts replacement during a time that will cause the least disruption.

IoT has emerged as a valuable tool that allows decision-makers more control over when maintenance or parts replacements occur. By providing real-time data from sensors installed on machinery, the IoT enables manufacturers to detect abnormalities and intervene before a machine breaks down suddenly.

One notable example of the IoT's impact on reducing manufacturing downtime comes from a global automotive component manufacturer that sought to minimize instances of fan failures inside brazing ovens. Traditionally, when the fans broke down, it took the factory representatives up to 36 hours to resolve the issue. However, by analyzing sensor data, the company's data scientists predicted that the fans would break down in 58 hours, allowing the maintenance team to intervene before the failure occurred.

Initially, the maintenance team was skeptical of the sensor data and doubted that the components needed replacement. However, their superiors insisted on following the data. The maintenance crew was surprised that half of the fan blades had disintegrated, confirming that the sensor data was accurate.

The example highlights one of the primary advantages of the IoT in reducing manufacturing downtime: the ability to detect abnormalities that humans may miss. By leveraging IoT data, manufacturing leaders can take proactive steps to maintain their critical equipment and minimize disruptions to production.

IoT provides a robust solution for manufacturers looking to minimize manufacturing downtime. By detecting abnormalities and providing real-time data, the technology enables manufacturers to make informed decisions, reduce equipment failures, and minimize costly downtime.

Minimizing downtimes by keeping people safe and healthy

The IoT has emerged as a promising solution for mitigating workplace injury risks and improving work safety. One of the primary benefits of the IoT is the use of connected wearables. These devices can track movements and provide real-time feedback to workers, helping them avoid repetitive stress injuries and other musculoskeletal disorders. By promoting better posture and movement, wearables can reduce fatigue, a major cause of workplace injuries.

Moreover, the data generated by these wearables can help managers identify areas of concern and implement proactive measures to prevent injuries before they occur. For example, analytics tools can be used to identify movement patterns associated with higher injury rates, allowing companies to take steps to address those risks and reduce downtime.

The use of wearables in manufacturing also can reduce costs associated with workplace injuries. The cost of lost productivity due to fatigue and injuries can quickly add up for companies with large workforces. Wearables can help reduce these costs by promoting a safer and more efficient work environment.

IoT is a powerful tool for reducing downtime caused by workplace injuries in the manufacturing sector. By leveraging connected wearables and data analytics, companies can promote worker safety and improve productivity, leading to better outcomes for both workers and the business as a whole.