The world of automation is in a constant state of evolution. From factory lines to robotics, the one constant is change. With the onset of the IIoT (Industrial Internet of Things), factories are now faster, smarter, and more efficient than ever. Every aspect of the manufacturing process is monitored, evaluated and improved through machine-to-machine communication. Interconnected sensors have been integrated throughout manufacturing and industrial processes.
They sense out-of-spec conditions that may alert to a problem within the process. If a motor is vibrating too much or if the temperature exceeds specifications, the sensor nodes will alert the controller of the problem. Gone are the days of scheduled maintenance. Now machines can alert the operator that they are approaching their life cycle limit or performing out-of-spec to allow maintenance to be performed as needed. This reduces man-hours spent trouble shooting, repairing, or replacing parts or systems, and may even prevent line-down situations.
This timely data provides manufacturers with savings in labor, materials, and production costs, and reduces waste as well. 
Sensor data is transmitted to the cloud or an edge computer to be processed and analyzed, enabling the controller to see process trends and optimize workflow. AI and machine learning improve the process to maximize efficiency. Work schedules can be optimized for peak times to ensure that workers and machines are working in tandem to produce the highest quality product and increase the overall production quantity. IIoT-enabled sensors also benefit advanced robotics, which are used throughout the entire automation space, from stacking pallets to moving products from one conveyor to another.
Many robots are now equipped with vision systems to improve their functionality. Machine vision allows robots to see patterns, shapes, and colors, enabling them to accurately grab and place products. This becomes very important to quality and safety. If a product is flawed, the robot is able to see the defect and remove it from the line. Machine vision also enhances safety by enabling cobots (collaborative robots) to perceive when a worker or obstacle is in the way of its swing.
A cobot will slow its swing considerably or stop completely if a person or object is in danger of being struck, and it will hold that position until the person or obstacle has been cleared from its path. IIoT and automation are far more important now than they were just a few short years ago. Thanks to a world-wide pandemic and a need to think greener, it has become strikingly clear that factories need to become more automated, smarter, and more interconnected. With labor shortages as they are and the increased cost of doing business, automating is key to remaining successful during the next 10 years.
