- Global spending on IIoT Platforms for Manufacturing is predicted to grow from $1.67B in 2018 to $12.44B in 2024, attaining a 40% compound annual growth rate (CAGR) in seven years.
- IIoT platforms are beginning to replace MES and related applications, including production maintenance, quality, and inventory management, which are a mix of Information Technology (IT) and Operations Technology (OT) technologies.
- Connected IoT technologies are enabling a new era of smart, connected products that often expand on the long-proven platforms of everyday products. Capgemini estimates that the size of the connected products market will be $519B to $685B by 2020.
These and many other fascinating insights are from IoT Analytics’ study, IIoT Platforms For Manufacturing 2019 – 2024 (155 pp., PDF, client access reqd). IoT Analytics is a leading provider of market insights for the Internet of Things (IoT), M2M, and Industry 4.0. They specialize in providing insights on IoT markets and companies, focused market reports on specific IoT segments and Go-to-Market services for emerging IoT companies. The study’s methodology includes interviews with twenty of the leading IoT platform providers, executive-level IoT experts, and IIoT end users. For additional details on the methodology, please see pages 136 and 137 of the report. IoT Analytics defines the Industrial loT (lloT) as heavy industries including manufacturing, energy, oil and gas, and agriculture in which industrial assets are connected to the internet.
The seven things you need to know about IIoT in manufacturing include the following:
- IoT Analytics’ technology architecture of the Internet of Things reflects the proliferation of new products, software and services, and the practical needs manufacturers have for proven integration to make the Industrial Internet of Things (IIoT) work. IoT technology architectures are in their nascent phase, showing signs of potential in solving many of manufacturing’s most challenging problems. IoT Analytics’ technology architecture shown below is designed to scale in response to the diverse development across the industry landscape with a modular, standardized approach.
- IIoT platforms are beginning to replace MES and related applications, including production maintenance, quality, and inventory management, which are a mix of Information Technology (IT) and Operations Technology (OT) technologies. IoT Analytics is seeing IIoT platforms begin to replace existing industrial software systems that had been created to bridge the IT and OT gaps in manufacturing environments. Their research teams are finding that IIoT Platforms are an adjacent technology to these typical industrial software solutions but are now starting to replace some of them in smart connected factory settings. The following graphic explains how IoT Analytics sees the IIoT influence across the broader industrial landscape:
- Global spending on IIoT Platforms for Manufacturing is predicted to grow from $1.67B in 2018 to $12.44B in 2024, attaining a 40% compound annual growth rate (CAGR) in seven years. IoT Analytics is finding that manufacturing is the largest IoT platform industry segment and will continue to be one of the primary growth catalysts of the market through 2024. For purposes of their analysis, IoT Analytics defines manufacturing as standardized production environments including factories, workshops, in addition to custom production worksites such as mines, offshore oil gas, and construction sites. The lloT platforms for manufacturing segment have experienced growth in the traditionally large manufacturing-base countries such as Japan and China. IoT Analytics relies on econometric modeling to create their forecasts.
- In 2018, the industrial loT platforms market for manufacturing had an approximate 60%/40% split for within factories/outside factories respectively. IoT Analytics predicts this split is expected to remain mostly unchanged for 2019 and by 2024 within factories will achieve slight gains by a few percentage points. The within factories type (of lloT Platforms for Manufacturing) is estimated to grow from a $1B market in 2018 to a $1.5B market by 2019 driven by an ever-increasing amount of automation (e.g., robots on the factory floor) being introduced to factory settings for increased efficiencies, while the outside factories type is forecast to grow from $665M in 2018 to become a $960M market by 2019.
- Discrete manufacturing is predicted to be the largest percentage of Industrial IoT platform spending for 2019, growing at a CAGR of 46% from 2018. Discrete manufacturing will outpace batch and process manufacturing, becoming 53% of all IIoT platform spending this year. IoT Analytics sees discrete manufacturers pursuing make-to-stock, make-to-order, and assemble-to-order production strategies that require sophisticated planning, scheduling, and tracking capabilities to improve operations and profitability. The greater the production complexity in discrete manufacturing, the more valuable data becomes. Discrete manufacturing is one of the most data-prolific industries there are, making it an ideal catalyst for IIoT platform’s continual growth.
- Manufacturers are most relying on IIoT platforms for general process optimization (43.1%), general dashboards & visualization (41.1%) and condition monitoring (32.7%). Batch, discrete, and process manufacturers are prioritizing other use cases such as predictive maintenance, asset tracking, and energy management as all three areas make direct contributions to improving shop floor productivity. Discrete manufacturers are always looking to free up extra time in production schedules so that they can offer short-notice production runs to their customers. Combining IIoT platform use cases to uncover process and workflow inefficiencies so more short-notice production runs can be sold is driving Proof of Concepts (PoC) today in North American manufacturing.
- IIoT platform early adopters prioritize security as the most important feature, ahead of scalability and usability. Identity and Access Management, multifactor-factor authentication, consistency of security patch updates, and the ability to scale and protect every threat surface across an IIoT network are high priorities for IIoT platform adopters today. Scale and usability are the second and third priorities. The following graphic compares IIoT platform manufacturers’ most important needs:
For more information on the insights presented here, check out IoT Analytics’ report: IIoT Platforms For Manufacturing 2019 – 2024.
- 99% of mid-market manufacturing executives are familiar with Industry 4.0, yet only 5% are currently implementing or have implemented an Industry 4.0 strategy.
- Investing in upgrading existing machinery, replacing fully depreciated machines with next-generation smart, connected production equipment, and adopting real-time monitoring including Manufacturing Execution Systems (MES) are manufacturers’ top three priorities based on interviews with them.
- Mid-market manufacturers getting the most value out of Industry 4.0 excel at orchestrating a variety of technologies to find new ways to excel at product quality, improve shop floor productivity, meet delivery dates, and control costs.
- Real-time monitoring is gaining momentum to improve order cycle times, troubleshoot quality problems, improve schedule accuracy, and support track-and-trace.
These and many other fascinating insights are from Industry 4.0: Defining How Mid-Market Manufacturers Derive and Deliver Value. BDO is a leading provider of assurance, tax, and financial advisory services and is providing the report available for download here (PDF, 36 pp., no opt-in). The survey was conducted by Market Measurement, Inc., an independent market research consulting firm. The survey included 230 executives at U.S. manufacturing companies with annual revenues between $200M and $3B and was conducted in November and December of 2018. Please see page 2 of the study for additional details regarding the methodology. One of the most valuable findings of the study is that mid-market manufacturers need more evidence of Industry 4.0, delivering improved supply chain performance, quality, and shop floor productivity.
Insights from the Shop Floor: Machine Upgrades, Smart Machines, Real-Time Monitoring & MES Lead Investment Plans
In the many conversations I’ve had with mid-tier manufacturers located in North America this year, I’ve learned the following:
- Their top investment priorities are upgrading existing machinery, replacing fully depreciated machines with next-generation smart, connected production equipment, and adopting real-time monitoring including Manufacturing Execution Systems (MES).
- Manufacturers growing 10% or more this year over 2018 excel at integrating technologies that improve scheduling to enable more short-notice production runs, reduce order cycle times, and improve supplier quality.
Key Takeaways from BDO’s Industry 4.0 Study
- Manufacturers are most motivated to evaluate Industry 4.0 technologies based on the potential for growth and business model diversification they offer. Building a business case for any new system or technology that delivers revenue, even during a pilot, is getting the highest priority by manufacturers today. Based on my interviews with manufacturers, I found they were 1.7 times more likely to invest in machine upgrades and smart machines versus spending more on marketing. Manufacturers are very interested in any new technology that enables them to accept short-notice production runs from customers, excel at higher quality standards, improve time-to-market, all the while having better cost visibility and control. All those factors are inherent in the top three goals of business model diversification, improved operational efficiencies, and increased market penetration.
- For Industry 4.0 technologies to gain more adoption, more use cases are needed to explain how traditional product sales, aftermarket sales, and product-as-a-service benefit from these new technologies. Manufacturers know the ROI of investing in a machinery upgrade, buying a smart, connected machine, or integrating real-time monitoring across their shop floors. What they’re struggling with is how Industry 4.0 makes traditional product sales improve. 84% of upper mid-market manufacturers are generating revenue using Information-as-a-Service today compared to 67% of middle market manufacturers overall.
- Manufacturers who get the most value out of their Industry 4.0 investments begin with a customer-centric blueprint first, integrating diverse technologies to deliver excellent customer experiences. Manufacturers growing 10% a year or more are relying on roadmaps to guide their technology buying decisions. These roadmaps are focused on how to reduce scrap, improve order cycle times, streamline supplier integration while improving inbound quality levels, and provide real-time order updates to customers. BDOs’ survey results reflect what I’m hearing from manufacturers. They’re more focused than ever before on having an integrated engagement strategy combined with greater flexibility in responding to unique and often urgent production runs.
- Industry 4.0’s potential to improve supply chains needs greater focus if mid-tier manufacturers are going to adopt the framework fully. Manufacturing executives most often equate Industry 4.0 with shop floor productivity improvements while the greatest gains are waiting in their supply chains. The BDO study found that manufacturers are divided on the metrics they rely on to evaluate their supply chains. Upper middle market manufacturers are aiming to speed up customer order cycle times and are less focused on getting their total delivered costs down. Lower mid-market manufacturers say reducing inventory turnover is their biggest priority. Overall, strengthening customer service increases in importance with the size of the organization.
- By enabling integration between engineering, supply chain management, Manufacturing Execution Systems (MES) and CRM systems, more manufacturers are achieving product configuration strategies at scale. A key growth strategy for many manufacturers is to scale beyond the limitations of their longstanding Make-to-Stock production strategies. By integrating engineering, supply chains, MES, and CRM, manufacturers can offer more flexibility to their customers while expanding their product strategies to include Configure-to-Order, Make-to-Order, and for highly customized products, Engineer-to-Order. The more Industry 4.0 can be shown to enable design-to-manufacturing at scale, the more it will resonate with senior executives in mid-tier manufacturing.
- Manufacturers are more likely than ever before to accept cloud-based platforms and systems that help them achieve their business strategies faster and more completely, with analytics being in the early stages of adoption. Manufacturing CEOs and their teams are most concerned about how quickly new applications and platforms can position their businesses for more growth. Whether a given application or platform is cloud-based often becomes secondary to the speed and time-to-market constraints every manufacturing business faces. The fastest-growing mid-tier manufacturers are putting greater effort and intensity into mastering analytics across every area of their business too. BDO found that Artificial Intelligence (AI) leads all other technologies in planned use.
- Sales, Marketing and Operations are most active early adopters of IoT today.
- Early adopters most often initiate pilots to drive revenue and gain operational efficiencies faster than anticipated.
- 32% of enterprises are investing in IoT, and 48% are planning to in 2019.
- IoT early adopters lead their industries in advanced and predictive analytics adoption.
These and many other fascinating insights are from Dresner Advisory Services’ latest report, 2018 IoT Intelligence® Market Study, in its 4th year of publication. The study concentrates on end-user interest in and demand for business intelligence in IoT. The study also examines key related technologies such as location intelligence, end-user data preparation, cloud computing, advanced and predictive analytics, and big data analytics. “While the market is still in an early stage, we believe that IoT Intelligence, the means to understand and leverage IoT data, will continue to expand as organizations mature in their collection and leverage of sensor level data,” said Howard Dresner, founder, and chief research officer at Dresner Advisory Services. 70% of respondents work at North American organizations (including the United States, Canada, and Puerto Rico). EMEA accounts for about 20%, and the remainder is distributed across Asia-Pacific and Latin America. Please see pages 11, 15 through 18 of the study for specifics regarding the methodology and respondent demographics.
Key insights gained from the study include the following:
- Sales, Marketing and Operations are most active early adopters of IoT today. Looking to capitalize on IoT’s potential to gain real-time customer feedback on products’ and services’ performance, Sales and Marketing lead all departments in their prioritizing IoT’s value in the enterprises. 12% of Operations leaders say that IoT is critical to attaining their goals. Executive Management and Finance have yet to see the value that Sales, Marketing and Operations do.
- Manufacturers see IoT as the most critical to achieving their product quality, production scheduling and supply chain orchestration goals. Insurance industry leaders also view IoT as critical to operations as their business models are now concentrating on automating inventory and safety management. Insurance firms also track vehicles in shipping and logistics fleets to gain greater visibility into how route operations can be optimized at the lowest possible risk of accidents. Financial Services and Healthcare are the next most interested in IoT with Higher Education and Business Services assign the lowest levels of importance by industry.
- Investment in IoT analytics, application development and defining accurate, reliable metrics to guide development is the most critical aspect of IoT adoption today. Investments in the data supply chain including data capture, movement, data prep, and management is the second-most critical area followed by investments in IoT infrastructure. Analytics, application development, and accurate, reliable metrics guiding DevOps are consistent with the study’s finding that early adopters have an excellent track record adopting and applying advanced and predictive analytics to challenging logistical, operations, sales, and marketing problems.
- IoT early adopters or advocates prioritize dashboards, reporting, IoT use cases that provide data streams integral to analytics, advanced visualization, and data mining. IoT early adopters and the broader respondent base differ most in the prioritization of IT analytics, location intelligence, integration with operational processes, in-memory analysis, open source software, and edge computing. The data reflects how IoT early adopters quickly become more conversant in emerging technologies with the goal of achieving exponential scale across analytics and IoT platforms.
- The criticality of advanced and predictive analytics to all leaders surveyed is at an all-time high. Attaining a (weighted-mean) importance score of 3.6 on a 5.0 scale, advanced and predictive analytics is today considered “critical” or “very important” to a majority of respondents. Despite a mild decline in 2017, importance sentiment (the perceived criticality of advanced and predictive analytics) is on an uptrend across the five years of our study. Mastery of advanced and predictive analytics is a leading indicator of IoT adoption, indicating the potential for more analytics pilots and in-production IoT projects next year.
- The most valuable features for advanced and predictive analytics apps include support for a range of regression models, hierarchical clustering, descriptive statistics, and recommendation engine support. Model management is important to more than 90% of respondents, further indicating IoT analytics scale is a goal many are pursuing. Geospatial analysis (highly associated with mapping, populations, demographics, and other web-generated data), Bayesian methods, and automatic feature selection is the next most required series of features.
- Access to advanced analytics for predictive and temporal analysis is the most important usability benefit to IoT adopters today. Second is support for easy iteration, and third is a simple process for continuous modification of models. The study evaluated a detailed set of nine usability benefits that support advanced and predictive activities and processes. All nine benefits are important to respondents, with the last one of a specialist not being required important to a majority of them at 70%.
- 93% of global product leaders say that predictive maintenance combined with real-time equipment monitoring enabled by integration is a must-have for factory planning today.
- 75% of global product leaders plan to implement factory of the future initiatives and programs in the next five years or less, starting with Industry 4.0
- 67% of automotive executives expect that new technologies enabled by real-time integration will enable their teams to reach and exceed lean management and continuous improvement goals starting this year and accelerating through 2030.
Boston Consulting Group’s recent article, The Factory of the Future provides insights into a recent global survey the consulting firm conducted of more than 750 manufacturing product leaders from leading companies in three industrial sectors: automotive (which includes suppliers and original equipment manufacturers, or OEMs), engineered products, and process industries. The survey’s objective is to define the vision for the factory of the future in 2030. Determining long-term benefits and the roadmap to implementation are also goals of the study Boston Consulting Group (BCG) and its research partner, the Laboratory for Machine Tools and Production Engineering at RWTH Aachen University, achieved. The Factory of the Future is a vision for how manufacturers should enhance production by making improvements in three dimensions: plant structure, plant digitization, and plant processes.
5 Ways Integration Fuels The Factory Of The Future’s Growth
Real-time integration based on intelligent objects that connect diverse enterprise systems including SAP, Salesforce and others is the foundation that manufacturing companies must adopt to excel in their Factory of the Future efforts. These real-time objects illustrate the future of Application Programmer Interfaces (API). APIs that will fuel and drive the Factory of the Future will enrich each real-time integration points across manufacturing networks. Intelligent Objects pervasively used today are the precursors to the most valuable APIs that will enable Factories of the Future tomorrow. With APIs continually improving and gaining the capability to provide insight and intelligence, the essential role of real-time integration in all factories of the future becomes clear.
The following are the five ways integration is enabling the Factory of the Future today:
- Real-time integration enables the value chains supporting the Factories of the Future to continually accelerate, excel and improve with additional insight that drives future growth strategies. Bringing greater intelligence into each integration point across the value chains supporting the Factories of the Future leads to new technologies delivering greater lean management benefits. Real-time integration will deliver strong benefits in the areas of lean management, predictive maintenance, modular line setups, and the orchestration and collaboration of smart robots.
- The Implementation Roadmap for the Factory of the Future shows how critical real-time integration is to the Factory of the Future’s vision being attained. Multidirectional layouts, modular line setups, sustainable production, the orchestration of smart and collaborative robotics and attainment of big data and analytics plans all are dependent on real-time integration. The following graphic from the study illustrates just how central integration is to the optimizing of plant structure and plant digitization.
- By integrating large-scale enterprise systems including those from SAP, Salesforce and others with legacy, 3rd party and homegrown systems, every area of production quality will improve. The most urgent need global manufacturers have is finding new ways to improve product, process and service quality without raising costs. Improving the quality of these three dimensions makes any manufacturer more trusted and successful in selling next-generation products. By aggregating data using real-time integration so that Big Data and advanced analytics can be used to find new patterns, some of the world’s most well-known manufacturers are excelling on product quality. To produce cylinder heads at its plant in Untertürkheim, Germany, Mercedes-Benz uses predictive analytics to examine more than 600 parameters that influence quality. Mercedes-Benz is an early adopter of using Big Data and advanced analytics to improve quality management and bring high precision to engineering. Bosch has implemented software that analyzes data about its production of fuel injectors in real time. The software monitors process adherence and recognizes trends. It automatically transmits information about deviations to operators, allowing them to improve the process accordingly.
- Real-time integration across and within manufacturing systems enables multi-directional layouts of production workflows. The Audi R8 manufacturing facility in Heilbronn, Germany, does not have a fixed conveyor so the teams there has greater multidirectional flexibility in building customized vehicles. Real-time integration across the Audi factory floor is essential to provide R8 production teams with the specifics of how they can best collaborate and deliver the highest quality vehicles in the shortest amount of time. Real-time integration is enabling driverless transport systems, guided by a laser scanner and radio frequency identification technology in the floor, which moves the car bodies through the assembly process. These systems enable assembly layout changes quickly with no impact on existing production. Enabling real-time integration often involves extensive field mapping between different systems, which is a lengthy and error-prone process. Integration technology provider enosiX has developed a unique, real-time integration technology that obsoletes the need for field mapping and supports bi-directional data updates.
- Enabling the Factory of the Future’s production operations to flex in response to rapidly changing customer requirements is entirely dependent on real-time, reliable integration of production and customer-facing systems. The implications of the study on the future of manufacturing underscore just how critical it is for manufacturers to be agile enough to create entirely new business models while gaining insight and intelligence into how they can continually improve lean manufacturing. When real-time integration unifies a value chain for any manufacturer, their speed, scale and ability to simplify the complex processes required to serve customers turns into a formidable competitive advantage.
- 35% of companies adopting Industry 4.0 predict revenue gains over 20% in the next five years.
- Data analytics and digital trust are the foundations of Industry 4.0.
- Cost-sensitive industries including semiconductors, electronics, and oil and gas are the most focused on adopting Industry 4.0, with 80% of companies in these industries saying it is one of their top priorities.
The recent article by Boston Consulting Group (BCG), Sprinting To Value In Industry 4.0, provides insights into how real-time integration between enterprise systems is an essential catalyst for Industry 4.0 growth. Industry 4.0 focuses on the end-to-end digitization of all physical assets and integration into digital ecosystems with value chain partners encompassing a broad spectrum of technologies. BCG surveyed 380 US-based manufacturing executives and managers at companies representing a wide range of sizes in various industries to complete the study.
Industry 4.0 Is At An Inflection Point Today
Having attained initial results from Industry 4.0 initiatives, many manufacturers are moving forward with the advanced analytics and Big Data-related projects that are based on real-time integration between CRM, ERP, 3rd party and legacy systems. A recent Price Waterhouse Coopers (PwC) study of Industry 4.0 adoption, Industry 4.0: Building The Digital Enterprise (PDF, no opt-in, 36 pp.) found that 72% of manufacturing enterprises predict their use of data analytics will substantially improve customer relationships and customer intelligence along the product life cycle. Real-time integration enables manufacturers to more effectively serve their customers, communicate with suppliers, and manage distribution channels. Of the many innovative start-ups taking on the complex challenges of integrating cloud and on-premise systems to streamline revenue-generating business processes, enosiX shows potential to bridge legacy ERP and cloud-based CRM systems quickly and deliver results.
There are many more potential benefits to adopting Industry 4.0 for those enterprises who choose to create and continually strengthen real-time integration links across the global operations. Recent research completed by Boston Consulting Group and PwC highlight several of them below:
- Manufacturers expect to gain the greatest value from Industry 4.0 by reducing manufacturing costs (47%), improving product quality (43%) and attaining operations agility (42%). 89% of all manufacturers see an opportunity to use Industry 4.0 to improve manufacturing productivity. Reducing supply chain costs (37%), enabling product innovation (33%) and attaining faster time-to-market (31%) are the next level of benefits manufacturers expect to attain. The following graphic provides an analysis of where manufacturers see Industry 4.0 having the greatest impact on their organizations.
- Manufacturers are gaining the greatest value from Industry 4.0 by creating pilot projects that create flexible, agile real-time platforms supporting new business models with real-time integration. Industry 4.0’s focus on enabling end-to-end digitization of all physical assets and integration into digital ecosystems relies on real-time integration to succeed. For manufacturers in cost-sensitive industries, the urgency of translating the vision of digital transformation into results is key to their future growth. The more competitively intense an industry, the more essential real-time integration
- Investing in greater digitization and support for enterprise-wide integration is predicted to increase 118% by 2020 in support of Industry 4.0. 33% of manufacturers surveyed report they have a high level of digitization today, projected to increase to 72% by 2020. The leading areas of these investments include vertical value chain integration (72%), product development and engineering (71%), and customer access including sales channels and marketing (68%).
- New product development and optimizing existing products and services are the greatest areas of growth potential for analytics and Big Data using Industry 4.0 technologies and integration strategies through 2020. Industry 4.0 is revolutionizing the use of analytics and manufacturing intelligence, setting the foundation for greater optimization of overall business and control, better manufacturing, and operations planning, greater optimization of logistics and more efficient maintenance of production assets and machinery. By better orchestrating these strategic areas, manufacturers are going to be able to attain levels of accuracy and responsiveness to customers not achievable before.
- Globally, manufacturing enterprises expect to gain an additional 2.9% in digital revenues per year through 2020, with digitizing their existing product portfolios (47%) leading all other strategies, further underscoring the need for real-time integration. Introducing an entirely new digital product portfolio is the second most common strategy (44%) followed by creating and offering new digital services to external customers (42%). Just over a third (38%) plan to create and sell big data analytics services to external customers.