The question of how technologies like 5G and IoT will shape future factories centres on the advantages these technologies bring, and the subsequent opportunities they open up. These technologies represent a significant shift in how manufacturing operates, creating “smart” factories with real-time data exchange and machine-to-machine communications.
According to a Microsoft report that commissioned IoT Analytics, six key paradigms are important for manufacturers who were responded; scalability (72%), automation (70%), serviceability (67%), accessibility (62%), flexibility (58%) and interoperability (58%). It also found that automotive OEMs are arguably the most advanced in adopting technologies for the factory, as 100% reported they had containerised workloads and 93% reported their organisations are using at least one device management solution.
To achieve the paradigms discussed, manufacturers will need to be smarter in the technologies they choose to adopt. 5G and IoT are no exception.
5G in the future factories
Because 5G delivers increased speeds, reduced latency and the ability to connect a vast number of devices simultaneously, these capabilities translate into key benefits:
Ultra-Reliable Low Latency Communication (URLLC): One of the most important aspects of 5G is its ability to deliver latency as low as one millisecond. This low latency is valuable in applications that require immediate data processing and decision-making, such as for robotics and automated guided vehicles (AGVs). In a factory setting, this means that machines and systems can respond to commands in real time.
Massive Machine-Type Communications (mMTC): 5G can support the connection of a massive number of IoT devices within a geographic area. This capability is particularly important for smart factories, where thousands of sensors, machines, and devices need to communicate well. The density of connections that 5G can handle allows for monitoring and management of every aspect of the production environment.
Enhanced Mobile Broadband (eMBB): The sheer data throughput provided by 5G’s mobile broadband is just as important. This allows for the real-time transmission of high-resolution video, 3D models, and other data-intensive applications.
The role of IoT
Smart factories have IoT devices embedded throughout the production line, from sensors monitoring equipment performance, reducing downtime, and improving predictive maintenance. The integration of these devices creates a data-driven environment with key benefits:
Real-time data exchange: IoT enables the continuous collection and analysis of data from across the factory floor. This real-time data exchange allows manufacturers to monitor equipment, track their status, and receive alerts about potential issues before it becomes a larger problem. For example, predictive maintenance systems use data from IoT-enabled devices to anticipate when a machine could fail which allows maintenance teams to step in before any serious damage occurs.
Advanced robotics: The integration of IoT with robotics is a cornerstone of the connected factor, and future factories. IoT sensors and actuators embedded in robots allow them to perform tasks with greater precision and adaptability. For example, in an automotive assembly line, robots equipped with IoT sensors can adjust their movements based on the specific requirements of each vehicle model.
Machine-to-Machine (M2M) communications: IoT enables M2M communications. It’s especially important for creating flexible manufacturing systems where production lines can be reconfigured to accommodate different products. For example, in a factory creating consumer electronics, machines can automatically adjust their settings to switch from assembling smartphones to tablets without requiring manual reconfiguration.
The synergy of 5G and IoT
IoT provides the data collected by devices, while 5G provides the connectivity network needed to manage and process large data sets in real time. These technologies combined create new applications:
Digital Twins: One of the most exciting applications of 5G and IoT in manufacturing is arguably digital twins — virtual replicas of physical assets. Digital twins allow manufacturers to simulate and analyse the performance of machines and systems in real-time. With 5G’s high-speed connectivity, data from IoT sensors can be fed into the digital twin instantaneously. Generally speaking, the more data fed into a digital twin, the better, but accurate data collected by sensors is superior.
Improved supply chain visibility: Beyond the factory floor, 5G and IoT are improving visibility across the supply chain. IoT devices embedded in products and materials can track their location and condition throughout the supply chain, while 5G ensures that this data is transmitted in real-time. This kind of end-to-end visibility is valuable for manufacturers, particularly when it comes to responding quickly to any disruptions.
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