With the rise of Industry 4.0, Internet of Things (IoT) and artificial intelligence, today’s manufacturing landscape can be described as dynamic, intelligent and efficient. But this transition didn’t happen overnight. The industry successfully evolved past manual, outdated operations not just by integrating new technology, but also by prioritizing connectivity and leveraging data to ensure facilities remain flexible and resilient.
Smart manufacturing is no longer a suggestion; it’s a business imperative to ensure your facility maintains a competitive advantage. In fact, 92% of manufacturers surveyed by Deloitte believe that smart manufacturing will be the key to remaining competitive over the next three years. Now, the question becomes: how can you ensure your systems and operations are set up for success?
While there are more ways than one to ensure your facility is smart, connected and reliable, in this piece, we’ll focus on the foundational piece of the puzzle: data. Specifically, data-over-power technology and how these systems are transforming operations to unlock the benefits of smart manufacturing and limit disruption, dropouts and downtime.
1. Understanding data-over-power
Data-over-power technology, also known as Powerline Communication (PLC), is the new era of data communication in industrial applications. At a high level, PLC is a technology that enables data transmission over existing electrical power lines. It offers a flexible, cost-effective solution for connecting various industrial systems and devices without the need for additional communication infrastructure.
PLC allows for reliable communication in environments where wireless signals may be unreliable or obstructed. It can be used to integrate automation systems, control machinery, and monitor equipment, offering a scalable and easy-to-deploy solution for industrial connectivity, even in challenging environments.
As today’s manufacturing environments become more complex, dependable communication is key to keeping systems safe, efficient, and running without disruption. PLC combines power and secure data in a single system, without the common challenges of wireless or optical technologies.
2. Comparing against traditional data transmission solutions
If you’re considering data-over-power technology for your manufacturing operations, it’s important to understand where these systems excel in comparison to traditional solutions like Wi-Fi or optical. Reliability, scalability and security are key considerations for system communications. But not all solutions are created equal. Let’s compare.
Wi-Fi
While Wi-Fi is a priority solution in manufacturing facilities due to its high bandwidth and cost benefits, there are certain disadvantages in high-throughput environments. These systems can get easily overwhelmed when handling an influx of devices, leading to interference or dropouts. These systems also require IT setup and network security, making them vulnerable to ongoing troubleshooting and data breaches.
Optical
Optical is a great solution for facilities with a single runway. They require line-of-sight within manufacturing environments, which limits the application across today’s evolving facilities. While these are low-latency systems, they require complex alignment and specialized skills to install. This means higher upfront and maintenance costs and limited flexibility when looking to scale operations.
Data-Over-Power
While PLC systems may not be the most cost-effective as compared to Wi-Fi, they are the most secure and reliable. Certain PLC solutions note that they are immune to interference, supporting consistent operation and building trust with customers and staff. These systems are easily scalable, taking on more vehicles and supporting longer runs. And with low maintenance comes lower lifecycle costs.
3. Unlocking data’s benefits
Data has become more important than ever as manufacturers consider the benefits of automation and artificial intelligence. Automation and AI feed off data. Without first establishing a strong data foundation, there’s only so much operators can do with the AI tools available to them. System interference, communication lags, dropouts, etc., make datasets unclear and limit the time to analyze and digest insights.
Data is the key to smart manufacturing. It drives decision-making, supports automated systems, and highlights opportunities to limit downtime and mitigate potential disruptions. Without an overarching understanding of how your equipment moves and communicates, you cannot effectively plan and scale operations. Secure data communication between equipment, such as conductor rails, slip rings, cable reels, and more, allows facility managers to track real-time performance, improve productivity, and maintain safety for systems and employees alike.
4. Choosing the right partner
Your facility’s data needs are unique. But they don’t have to be complicated. By choosing a vendor partner that understands the specific challenges and goals of your systems, you can unlock the benefits of secure data communication to keep operations moving. Establishing trusted vendor partnerships is key in the age of automation and AI, as the goalposts for success and maintaining a competitive advantage tend to move.
As you consider these partnerships, look for a vendor with solutions that address critical gaps in current industrial communication systems. Ask yourself these questions: Can they offer you a more reliable, scalable, and secure solution where existing systems fall short? Do they have long-standing expertise in data communication systems? Is their suite of offerings deep enough for you to trust they are suggesting the right solution for you, not just what they have in stock?
Establishing a strong data foundation
The only constant in today’s digital age is that industries will continue to innovate and change. To navigate this, your facility needs to adopt smart manufacturing as a competitive advantage. Data is the key to success, and secure communication is critical to ensure you can tap into the tools available to you. By integrating the right data infrastructure and working with the right partners, you can enable efficient, reliable and scalable operations that are prepared for the future.
