Use of IoT in increasing opeartional efficiency in manufacturing plants- a case study
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Transcript of Use of IoT in increasing opeartional efficiency in manufacturing plants- a case study
WAYS TO INCREASE OPERATIONAL EFFICIENCY AT MANUFACTURING PLANTS- APPLICATION OF IOT-A CASE STUDY
MANISH SAXENA, Joint Advisor,
Telecom Regulatory Authority of India,
Regional Office, Jaipur
PROBLEM: HOW TO INCREASE OPERATIONAL EFFICIENCY AT MANUFACTURING PLANTS
Customers
Needs to address
Manufacturing Plants
There are many ways, IoT can help in increasing operational efficiency in manufacturing plants e.g. inventory
control and supply chain management. But one of the greatest advancement may be made possible by the IoT is
energy management .• How to minimize and optimize
energy consumption
TRADITIONAL SOLUTION
•Energy is often one of the largest expenses for manufacturers. Traditionally , most of the plants managers obtain energy consumption data from monthly utility bills or energy monitoring tools with limited data points.•Monthly utility bills are delivered after a substantial period post the end of the billing cycle. Further they often report energy use for entire manufacturing plants. This information is of little use for plant managers for identifying waste or enabling reduction of consumption.
IoT Solution
• Using device connectivity enabled by IoT, manufacturers can track energy consumption patterns at the device level. A sensor /actuator is installed at each of the machinery part/ energy consuming component to remotely monitor and control the energy consumed by that manufacturing equipment/component .• Machinery energy consumption data is also collected through the sensors and devices send periodic message regarding energy consumed to the controlling station may be in the same premises or at remote location of IoT company. This data is analyzed to help optimize the energy consumption in manufacturing process.
IoT SOLUTION AND BENEFITS
Benefits
By tracking each piece of machinery on the floor, managers and executive get granular
visibility into energy consumption, actionable insight about waste, increased
operational efficiencies, impending equipment failures, regulatory compliance
etc. Resource Utilization: Real time energy profiles allow manufacturers to detect off-
hours consumption, optimize manufacturing production schedules and
identify anomalies.Benchmarking: Manufacturer can
benchmark similar piece of equipment to find out systems that are not functioning
properly to detcet hidden operational inefficiencies and energy waste.
IOT SOLUTION AND BENEFITS
Predictive Maintenance: Manufacturer gets alerts for service when service is needed based on recognized unusal energy usage,
thus avoiding the high costs equipment downtime.
Efficient Production: Same or greater outputs with more efficient energy use due
to optimal manufacturing processes.
Operational Efficiency and Profitability: Increased
operational efficiencies made possible by this IoT solution of
device level energy management immediately affects the bottom line for
manufacturers. For example using predictive maintenance manufacturers can eliminate machinery failure , which is
costly and its associated down time which may be even more costly. Moreover with device-
level energy consumption data made possible by IoT,
manufacturer can reduce their wasteful consumption and hence their energy spent.
IoT SOLUTION AND BENEFITS
Feature Requirement CommentNetwork Area • Wide Extended area of manufacturing
plants and control/monitoring centre at remote location require significant signal coverage
Spectrum • Dedicated Quality of service of transmission is a crucial factor
Battery Life • Short/ N/A Device may be charged by factory supply
Connectivity cost
• Medium Associated with the type of technology.
Module Cost • Medium/High Price may not be an issue in big manufacturing plants
Bandwidth • Medium Data needed to monitor energy use in various components may be moderate.LPWA 2G 3G
TECHNOLOGIES
MOST LIKELY BUSINESS MODELBusiness Model Revenue of the IoT
companyDevice ownership
Costs-saving sharing Recurring IoT company
• The IoT company installs, operate and maintain the monitoring and control equipments/system with no upfront fees.• The end user (manufacturing plant) pays for the equipment rental from the energy savings generated by the IoT solution.
OPERATIONAL ISSUES & POLICY TOPICS
Network coverage
Business Model
Global deployment &
taxationLegal
framework in Cost-saving
business model
Operational Considerations
Policy areas
Mechanism to assess savings
in cost
THANKS