Industrial Internet of Things (IIoT): Detailed Overview

Stepping into the industrial operations niche, the convergence of cutting-edge technology has given rise to a transformative era known as the industrial Internet of Things (IIoT). This innovative integration of the digital realm with industrial processes marks a paradigm shift in how businesses approach efficiency, productivity, and overall operational excellence.

With sensors, connectivity, and data analytics, IIoT is a revolution that promises to redefine the landscape of industrial ecosystems by unlocking new possibilities and efficiencies across various sectors. Let's dive into the fascinating industry where machines meet data and usher in a new era of intelligent and connected industrial enterprises.

This review will unravel the core distinctions between IoT and IIoT, shedding light on the unique challenges and opportunities. Delving into the benefits of IIoT, we'll uncover its potential to revolutionize industrial processes while addressing critical aspects like security and performance issues.

Also, this journey extends to the practical aspects of IIoT, examining its implementation strategies and the crucial realm of asset management within this digital landscape and addressing common questions through an FAQ section.

What is the main difference between IoT and IIoT?

The industrial Internet of Things is a specialized branch of the broader IoT family. IoT covers a range of everyday applications like wearable devices, smart homes, and self-driving cars, while IIoT is convenient for industrial settings. Both have a common use in devices, machines, and infrastructure packed with sensors. In both IoT and IIoT, the data is sent over the Internet and processed by software.

Delving into the distinctions between IoT and Industrial IoT, it is essential to emphasize that IIoT is a specialized version, developed explicitly for industrial endeavors. They share many fundamental concepts and functionalities, but nuances set IIoT apart from typical IoT applications.

On the one hand, IoT caters to various sectors and user needs, focusing on more general applications. On the other hand, IIoT is focused on industrial settings, crafted for professionals navigating the intricacies of the industrial field. This is comparing a versatile tool for diverse tasks with a specialized tool designed for a specific job.

Users pursue slightly different objectives among IoT and IIoT. IoT implementation often revolves around enhancing efficiency, ensuring health and safety, and delivering improved user experiences. On the other side, IIoT is still focused on efficiency and safety and tends to be less user-centric. IoT finds its way into everyday consumer use with devices like smart thermostats and watches. At the same time, IIoT operates behind the scenes, embedded in industrial processes.

IIoT devices integrate with existing machinery, providing valuable data to users about their industrial equipment. It is a behind-the-scenes workhorse dedicated to streamlining industrial operations.

In situations where IoT devices encounter failure, the risk is relatively minimal because these devices are typically deployed on a small scale. IoT devices are generally not involved in critical processes that could pose threats or dangerous consequences if they malfunction, but IIoT devices operate within a networked environment. In the event of a failure, they can potentially lead to dangerous situations, especially when dealing with heavy machinery. The scope of impact is more significant in the industrial landscape compared to the relatively contained scenarios of IoT devices.

When companies develop new IoT devices, the primary objective is to increase convenience in the daily lives of users. The point of development is often directed towards improving comfort by meeting the high consumer demand for user-friendly solutions. Besides, the development of IIoT is typically centered around creating devices that enhance the efficiency of clients' operations. Industrial organizations, in their pursuit to stay competitive within their industry, require optimized processes. IIoT developers leverage data metrics to design devices that assist companies in cost reduction and efficiency enhancement.

Typically, IoT devices aren't required to be compatible with old-fashioned systems. These devices usually operate independently, so developers don't have to ensure backward compatibility, but IIoT devices often need compatibility with a range of legacy devices and machines present in industrial plants. These plants frequently feature equipment without digital interfaces or functionality. Many IIoT devices are designed to assist old equipment in providing digital data and accepting commands from IT systems.

Benefits of IIoT

IIoT devices employed in the manufacturing industry provide the following benefits.

More efficient machine utilization

The IIoT empowers manufacturers to link their machines to the internet. This connectivity provides manufacturers with real-time insights into machine health and key performance indicators (KPIs). These KPIs encompass metrics such as overall equipment effectiveness (OEE) and overall process effectiveness (OPE). Manufacturers can pinpoint and address the root causes of unplanned downtime by utilizing this data. Moreover, it lets them enhance machine utilization by indicating the necessity for preventive equipment maintenance.

Better predictive maintenance

Manufacturing companies invest millions in operational and maintenance costs for machinery. Equipment maintenance is crucial to preventing disruptions in production processes. Detecting downtime before it occurs can result in significant reductions in operational costs.

The industrial internet of things enables machines to predict failures in advance with the integration of sensors, data analytics, and cameras. This predictive capability allows manufacturers to establish strategic maintenance schedules, ensuring repairs are conducted only when necessary.

Manufacturers can implement vibrant, efficient, and automated manufacturing processes with autonomous maintenance schedules, reducing reliance on unpredictable maintenance personnel. This approach leads to well-planned maintenance processes, promising substantial cost savings by minimizing equipment failures and extending machine lifetimes.

More efficient service

IIoT technologies empower field service specialists to detect potential issues in customer equipment before they get down, allowing technicians to address problems proactively before they impact customers. These technologies furnish service with information about the required parts for a repair, ensuring that technicians have the necessary components on hand during service calls. This proactive approach enhances the efficiency and effectiveness of field service operations.

Better quality assurance

Manufacturers can employ connected sensors and devices like machine vision cameras, scales, and calipers, but also humidity and temperature sensors at quality check stations. Intelligent sensors bring a level of precision to the inspection process that surpasses manual inspections. Quality checkpoints can seamlessly integrate into the production process, ensuring early detection and resolution of defects before they progress down the line.

Better quality control

High-quality products and services are paramount for success in manufacturing. IIoT achieves this objective by offering real-time data on critical production parameters like temperature, pressure, humidity, and more. This data empowers businesses to uphold optimal conditions for production, ensuring a consistent and high standard of product quality. IIoT facilitates proactive measures to predict and prevent potential quality issues before they arise. Through the analysis of historical and gathered data patterns.

Improved safety

Safety is a top priority in industrial environments. IIoT elevates safety standards across diverse industries. IIoT helps companies actively monitor machinery and environmental conditions in real time, swiftly identifying potential troubles and taking immediate measures to address them before they become more serious.

Cost savings

IIoT offers cost reductions for businesses. Its ability to optimize operations, enhance product quality, and minimize unplanned downtime contributes significantly to substantial savings.

Moreover, IIoT proves effective in decreasing energy expenses. Through real-time monitoring and control of energy usage, businesses can strategically optimize their energy consumption patterns, resulting in noteworthy cost savings.

IIoT implementation

Integrating IIoT is a valuable and intricate endeavor. Companies should view IIoT implementation as a comprehensive digital transformation rather than a singular project. Achieving success in IIoT demands close coordination among management, engineering, IT, and OT teams, coupled with widespread support throughout the organization.

The industrial Internet of Things sounds revolutionary, and it promises to enhance operational efficiencies by integrating automation, connectivity, and analytics. However, the IIoT extends beyond specific manufacturing processes to encompass a broader spectrum of industries.

#1. Defining goals

The point of your IIoT project lies in establishing clear and measurable goals. What business challenges does your IIoT project aim to solve? IIoT should tackle specific business issues, including improvements in quality, heightened machine utilization, and expedited cycles of enhancement.

It's crucial to determine the questions you want your data to answer before embarking on data collection. Scrutinize, categorize, and distill information related to areas that are ripe for improvement.

#2. Identifying the measures (KPIs)

The company`s objectives need to be measured through key performance indicators (KPIs) and predefined success metrics. The promises of new technologies implemented by a company may fall short of expectations without a grounding in essential business metrics.

#3. Set a plan

Consider how to gather the necessary data to achieve your goals and which technologies can facilitate this data collection.

To answer these questions, you need to evaluate the connectivity status of your equipment. Most contemporary machines are designed to provide a wealth of information. They can be equipped with features like OPC or Ethernet connectivity. For legacy machines, a more intricate process is required, often involving sensors and an IoT gateway to bring them online.

Additionally, assess any adjustments needed for facility or network infrastructures, like installing Ethernet drops and running cables. Implementing such changes will require extra time. Also, consider securing the cooperation of individuals in your company with IT expertise because their approval may be necessary for implementing these changes.

#4. Launch a proof of concept

A proof of concept (POC) is referred to as a proof of value (PoV) and serves as an experiment aimed at addressing key questions like what value the technology brings to your company and what the return on investment is.

Planning a proof of value is crucial for strategy. Choose an area where you can showcase a rapid return on investment (ROI) on a small scale. Start with a small scope by establishing a clear timeframe and setting expectations with well-defined success metrics and a specific dataset for measurement.

#5. Get organizational approval

Use the insights obtained from your IIoT connections to determine the return on investment (ROI) achieved through your proof of concept. It's the opportune moment to present the project to management with the proven ROI of a successful POC.

Successful business transformations necessitate a cultural shift to support and sustain the initiative. Essential to this transformation is securing support and commitment from upper-level management, which provides crucial guidance for the project's trajectory.

#6. Expand the implementation

To transition from the POC to full implementation, you need to create a comprehensive plan. This plan offers clarity for the project, aligns actions with the overall vision, and serves as a reference for timelines and costs.

IIoT asset management

IIoT asset management involves monitoring and overseeing individual network-connected assets through deep packet inspection sensors to capture and report detailed asset information. This includes make, classification, location, operating system, serial number, application usage, and more.

The industrial Internet of Things stands at the heart of the industrial revolution, transforming various sectors, particularly asset management. IIoT is actively addressing long-standing challenges in optimal asset management through the integration of intelligent devices, sensors, and advanced analytics.

According to recent research by McKinsey & Company, IIoT has the potential to reduce maintenance costs by up to 20% and extend the lifespan of machinery by several years. This represents a significant breakthrough for organizations dealing with issues like unplanned downtime, inefficient maintenance schedules, and the substantial costs linked to asset replacement.

The integration of the IIoT into asset management is reshaping the economic landscape for businesses across various sectors. An advantage of this integration is the significant cost savings, primarily achieved through predictive maintenance. Predictive maintenance is a key application of IIoT, which empowers businesses to anticipate equipment failures before they occur. This enables strategic scheduling of maintenance activities during non-peak hours and avoids unexpected breakdowns that could disrupt operations.

The IIoT is playing an important role in revolutionizing asset management by prolonging the lifespan of assets. Businesses can monitor asset performance in real-time, streamline processes, and increase equipment longevity with the help of IIoT technology. This achievement goes through various essential mechanisms, such as predictive maintenance, real-time monitoring, and data-driven decision-making.

One of the most impactful ways IIoT contributes to extending asset longevity is through predictive maintenance. IIoT systems can detect patterns and anomalies that indicate possible failures before they happen by collecting and evaluating data from sensors built into equipment. This proactive approach enables organizations to schedule maintenance activities, preventing costly breakdowns and ultimately increasing the lifespan of their assets.

IIoT technology allows organizations to consistently monitor the real-time performance of their assets. This proactive approach enables them to promptly identify and address issues when they arise. It helps reduce the risk of equipment failure and prolongs the lifespan of assets. For example, a utility company employs IIoT sensors to monitor a steam turbine's temperature and pressure. If sensors detect numbers outside the acceptable range, the company can take immediate action to prevent the problem.

The influence of the IIoT on asset management is truly revolutionary. With the adoption of IIoT technology, organizations can realize substantial advancements in asset longevity, operational efficiency, and workplace safety. The integration of intelligent devices, sensors, and sophisticated analytics facilitates real-time monitoring, predictive maintenance, and data-driven decision-making, ushering in a new era of enhanced asset management.

With IIoT capabilities, businesses stand to achieve notable cost savings and extend the lifespan of assets and workplace safety, ultimately contributing to a more favorable return on investment. As the niche of IIoT continues to progress and mature, its profound impact on asset management is poised to amplify, presenting organizations with ever-expanding opportunities to optimize their operations and maximize overall returns.

The challenges and opportunities in IIoT

Opportunities in industrial IoT

The IIoT opens up various opportunities for businesses to enhance their operations and cut down on costs. One application of IIoT involves optimizing supply chain management through real-time data on inventory levels, product demand, and shipping times. This optimization can result in more efficient logistics, lower inventory costs, and increased customer satisfaction.

Supply chain

Supply chain management is IIoT technology equipped with sensor inventory that can improve the way supplies are handled. By autonomously placing orders just before items run out of stock, this technology reduces waste and ensures essential goods availability. Moreover, it allows employees to redirect their efforts toward other important tasks.

Retail

In the retail sector, IIoT technology holds the promise of making fast decisions and intelligent marketing decisions adapted to individual stores. Retail IIoT systems employ storefronts that automatically generate consumer interest and implement smart promotions. Retailers integrate IIoT technology to gain a substantial advantage over their competitors.

Building management

IIoT building management technology has the potential to simplify and enhance security. Climate control sensors get rid of the guesswork and frustration caused by manually adjusting a building's climate. Moreover, devices that monitor entry points and swiftly respond to potential threats contribute to boosting building security.

Tracking and maintenance

Real-time information on the condition and location of equipment allows for predictive maintenance, which reduces downtime and boosts overall productivity. This, in turn, leads to substantial cost savings and improved operational efficiency.

Furthermore, IIoT provides opportunities for quality control and process optimization. Real-time data on production processes, quality control measures, and supply chain logistics empowers businesses to optimize their operations, minimize waste, and improve product quality.

Challenges of IIoT

It is imperative to prioritize security and energy considerations in implementing IIoT systems. Cyber-attacks, data breaches, theft, and sabotage pose significant threats to sensitive data and operational continuity. Likewise, physical security threats like thefts can disrupt the functioning of IIoT systems.

Energy efficiency emerges as a critical factor, especially for IIoT devices operating in remote or constrained environments. Deploying energy-efficient protocols and computing systems becomes essential to minimizing energy consumption. It prevents increased operating costs, reduces device lifespan, and mitigates environmental impact.

Managing security and devices poses challenges for those overseeing an organization's IIoT infrastructure. As the number of IIoT devices continues to grow, having a robust IoT device management strategy becomes essential. The ability to accurately identify each IIoT device is crucial for preventing the use of unauthorized devices and for tasks like device upgrades.

Effective management is another issue in IIoT device management. Manufacturers regularly release firmware updates, and organizations need a streamlined process to assess devices for the latest firmware and deploy updates as needed. This process can cause some trouble because it should align with the organization's maintenance schedule to avoid disrupting ongoing operations.

IIoT security issues

Manufacturers developed IoT devices with limited attention to security, contributing to the perception that IoT devices lacked inherent security. Considering the similarities between IoT and IIoT devices, there's a need to assess the safety of using IIoT devices. Like any connected device, the security of IIoT devices should be estimated on a case-by-case basis.

While one manufacturer's device may be secure, another's may not. However, there is a growing emphasis on security among device manufacturers. Security measures in IIoT may include features like multifactor authentication, end-to-end encryption, and the establishment of custom authorization levels.

Security concerns in the IIoT can arise across all levels of cyber-physical systems, ranging from programmable controllers to legacy applications with unpatched vulnerabilities. A company must safeguard all endpoints on both wired and wireless networks. Ensuring the security of data during transmission and storage, and promptly addressing security vulnerabilities in applications that form part of IT infrastructure to address any security risks in IIoT.

Performance issues in IIoT

The IIoT offers numerous advantages but also comes with its share of performance issues. The interconnected nature of devices and the need for rapid data analysis pose potential failures such as inadequate device maintenance, lapses in ensuring a secure network service or data confidentiality, the absence of individual access control policies, and a lack of solutions for machine and human errors. Addressing these problems requires highly skilled staff to meet industrial requirements.

Connectivity technology serves as the foundation for all IoT systems, regardless of their complexity and application area. In industrial IoT environments, the growing number of online devices and sensors results in an expansion of endpoints, communication channels, and data storage solutions. This requires a diverse and well-balanced mix of data and networking protocols that meet specific security systems.

A lot of IIoT traffic remains unencrypted, posing a vulnerability where hackers can exploit weak points, such as obtaining user logins. Poor encryption practices are often associated with the use of old or not-upgraded communication technologies. Many of these outdated IIoT communication protocols lack inherent data encryption capabilities. It compels IoT developers to employ workarounds like VPNs, secure tunnels, gateways, or addressing encryption issues.

Many organizations report having shadow IIoT devices on their network, and the respondents admit those devices were connected without the knowledge of their security or IT teams. As a result, companies are unaware of how their devices communicate with each other, what information they gather and exchange, and whether this information is spread to third parties.

Conclusion

The IIoT stands at the forefront of a transformative era in industrial processes. Being a subset of the broader Industry 4.0 revolution, IIoT integrates smart technologies, connectivity, and data analytics into industrial ecosystems. Its impact promises enhanced asset management, predictive maintenance, real-time monitoring, and improved operational efficiency.

By connecting machines, sensors, and devices, IIoT enables real-time insights, data-driven decision-making, and the potential for considerable cost savings. Through predictive maintenance, organizations can proactively address equipment issues, reducing downtime and extending the lifespan of assets.

The implementation of IIoT requires careful planning, organization-wide collaboration, and a clear understanding of specific business goals. Successful IIoT adoption involves defining measurable objectives, identifying key performance indicators, and conducting proof-of-concept.

IIoT will continue to play its part in the next industrial revolution, driving innovation, efficiency, and collaboration across various domains. Do you want to bring IIoT to your system? Reach out to us to discover how Kaa can help your organization.

IIoT FAQ

What is IIoT, and how does it work?

IIoT refers to the integration of internet-connected devices, sensors, and machines in industrial settings. It works by collecting data from these connected devices, enabling real-time monitoring, analysis, and optimization of various processes in manufacturing.

What are the benefits of IIoT?

The benefits of IIoT include improved operational efficiency, predictive maintenance, cost reduction, real-time monitoring, enhanced safety, and better quality control in industrial processes.

What are the challenges of IIoT?

The challenges of IIoT include security concerns, interoperability issues, data privacy risks, high implementation costs, and the need for skilled professionals to manage and maintain the systems.

What is a smart factory?

A smart factory is essentially a factory equipped with IIoT connectivity. It allows the capture and storage of valuable process data. This capability enables smart manufacturing by establishing centralized networks that interconnect assets and facilitate digital connectivity.

What is the IIoT network problem?

The network problems in IIoT include issues with reliability, latency, bandwidth constraints, and the need for robust connectivity solutions to ensure seamless communication among devices.

What is advanced industrial analytics?

Advanced analytics is a specialized area within analytics. It utilizes sophisticated statistical models, advanced tools, and predictive capabilities to discern future trends, events, and behaviors specifically tailored for industrial manufacturing processes.