Today, the most complex problem for organizations is to pursue technical advancement in legacy systems and machinery. There is no unified visibility of the industrial processes as 54% of US manufacturers say they lack a unified view of their plant and building information. It is also found that 40% of profits are lost due to unplanned downtime in manufacturing units and an average $1B revenue is lost each year by manufacturing companies.1
To increase the ROI and production capabilities, technology advancement or digitization is important for organizations. Apparently, organizations are rapidly moving towards digital transformation, but it is not easy to adapt. A lot of questions come to one’s mind when thinking about adopting digitization, such as:
Should organizations consider digitization?How much implementation time does digital transformation require?Will it increase profitability?
Certainly, there are a lot of challenges in implementing digital transformation. Let’s have a look at the challenges of industrial transformation and how current technologies like IoT and Cloud help in this.
Challenges of industrial organizations
A typical industrial plant or factory consists of many heterogeneous components, machines, and devices such as legacy devices, PLCs, valves & actuators, conveyor belts, and other machinery. Industries like oil & gas, manufacturing plants consist of huge mechanical parts like drilling machines, pipelines, robotic arm, packaging machine setups, etc. The most challenging task is to connect the current OPC UA (Open Platform Communications Unified Architecture) system to the cloud.
Along with this, monitoring these devices in real time is a challenge because of the lack of visibility. A failure of any component can cause downtime that can eventually affect the productivity and profits projected from these assets. However, these challenges have started diminishing with rapidly growing technologies and the adoption of the Industry 4.0 concept, which is leading this transformation.
Digital transformation with Industry 4.0
With the Industry 4.0 adoption, machines and devices can be connected, and legacy devices can be monitored with the latest sensors and transducers in the market. These connected devices and sensor data provide the benefit of HMI (Human machine interface). Both embedded and stand-alone HMIs help improve working and monitoring of factory plants as well as processes, driving a big change in the efficiency of the overall manufacturing unit.
Another benefit of Industry 4.0 concept is it enables predictive maintenance. This simply means that a machine should not be repaired too late (after it fails), nor too early (when it is still in good condition). To increase productivity and reduce maintenance costs, sensors can be integrated with machines to constantly monitor the production machinery.
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