Leveling the Smart Manufacturing Playing Field With IT/OT Convergence

The manufacturing industry is undergoing a digital transformation, driven by technologies like Industry 4.0, the Industrial Internet of Things (IIoT), and smart factories, which represent a significant shift in how manufacturers operate, compete, and innovate. These advancements are no longer exclusive to large corporations with deep pockets. Small and medium-sized manufacturers (SMMs) can now harness the power of Smart Manufacturing by embracing the convergence of operational technology (OT) and information technology (IT). 

OT/IT Convergence: Bridging the Gap 

In simple terms, OT is the combination of hardware and software that controls physical processes (machinery, HMIs, PLCs, Maintenance systems, etc.) that are traditionally isolated. IT, on the other hand, is the technology and networking that manages data, communication, and business processes. 

IT/OT convergence involves connecting these two realms to gain unprecedented insights into manufacturing operations. By capturing and analyzing operational data, SMMs can make data-driven decisions to improve efficiency, reduce costs, and enhance product quality. 

Capturing and Analyzing Operational Data 

One of the biggest hurdles for SMMs is the misconception that Smart Manufacturing requires a complete overhaul of existing equipment. This is simply not true. Any device (even non-automated tooling systems) with standard mechanisms can provide industrial data to a user application. 

Sensors: For older machines without built-in connectivity, sensors are a game-changer. They can monitor parameters like temperature, pressure, vibration, and energy consumption. This data can be transmitted wirelessly to a central system for analysis. 

Data Acquisition Systems: Devices like Programmable Logic Controllers (PLCs) or specialized solutions like the LIMS Appliance developed by LECS can collect and organize data from various sources, including sensors, OEM machine protocol, and other inputs. They then aggregate and organize the data, making it easier to analyze for decision making. 

Cameras and Computer Vision: Cameras mounted near workstations can capture visual data to monitor production rates, detect defects, and even track inventory levels using advanced analytics. 

Cloud-Based Platforms: These platforms provide a scalable and secure way to store, analyze, and visualize operational data. While cloud platforms are not required, they often offer built in tools and features like real-time dashboards, predictive analytics, and machine learning capabilities. 

Glimpsing the Future 

Once SMMs achieve success with their first pilot, the experience is often a revelation. They realize just how accessible and actionable their data can be, allowing them to make measurable improvements without replacing a single machine. However, when the benefits of automation outweigh the costs of new equipment, it does make sense to upgrade. Still, transitioning to Smart Manufacturing doesn't have to be a daunting, all-at-once endeavor. SMMs can take a planned, gradual approach, strategically replacing legacy equipment with smart machines as budgets allow and priorities dictate. Upgrading in phases minimizes disruption, allows for continuous learning and adaptation, and spreads out the investment cost over time. 

While the initial expenditure may appear difficult to justify, the long-term savings and competitive advantages make a compelling argument for upgrading. Smart machines reduce labor costs, optimize energy consumption, and improve material usage. They also enable real-time, data-driven decision-making, allowing you to identify bottlenecks, predict future trends, and stay ahead of the curve. 

Investing in smart machinery isn't just about keeping up with the times; it's a strategic move that offers significant cost benefits and a strong ROI. By reducing downtime, improving quality control, and increasing overall productivity, these machines quickly pay for themselves. Imagine minimizing waste, streamlining production, and getting products to market faster – all thanks to the power of smart technology. 

Changing the Culture: Upskilling and Empowering Staff 

Adopting Smart Manufacturing technologies is not just about hardware and software. It's also about investing in the industry’s most valuable asset: the people. 

When implementing modern technologies, it's crucial to provide employees with the training and resources they need to understand and use them effectively. This might involve technical training on specific software platforms, data analysis techniques, programming languages, and cybersecurity, as well as soft skills development to improve communication and critical thinking. Front-line staff need to feel empowered to take action based on real-time data.  

The Future is Smart 

Smart Manufacturing technologies bring numerous benefits to SMMs, including improved efficiency, reduced costs, enhanced quality, and increased competitiveness. By embracing IT/OT convergence and adopting smart technologies, SMMs can level the playing field and thrive in the digital age. 

The convergence of OT and IT is transforming the manufacturing landscape. The key is to start small, focus on specific needs, and engage with experts who can help them navigate the process.  

Our continuing blog series on Smart Manufacturing for Small and Medium-Sized Manufacturers will help you unlock the potential of Smart Manufacturing in your organization. Don’t miss an installment. Sign up now to discover practical tips, real-life examples, and more! Or fill out the form below to speak with an expert. We can help you get started on your Smart Manufacturing journey today.