Industrial Internet of Things (IIoT) presents integration architecture challenges that once solved can enable use cases that deliver fast-growing revenue opportunities.
ISA-95 addressed the rise of global production and distributed supply chains yet are still deficient on the issue of data and security, specifically the proliferation of IIoT sensors, which are the real security perimeter of any manufacturing business.
Finding new ways to excel at predictive maintenance, and cross-vendor shop floor integration are the most promising applications.
IIoT manufacturing systems are quickly becoming digital manufacturing platforms that integrate ERP, MES, PLM and CRM systems to provide a single unified view of product configurations.
The following are the key takeaways from the study:
Capturing IIoT’s full value potential will require more sophisticated integrated approaches than current automation protocols provide. IIoT manufacturing systems are quickly becoming digital manufacturing platforms that integrate ERP, MES, PLM and CRM systems to provide a single unified view of product configurations and support the design-to-manufacturing process. Digital manufacturing platforms are already enabling real-time monitoring to the machine and shop floor level. The data streams real-time monitoring is delivering today is the catalyst leading to greater real-time analytics accuracy, machine learning adoption and precision and a broader integration strategy to the PLC level on legacy machinery. Please click on the graphic to expand for easier reading.
Inconsistent data structures at the machine, line, factory and company levels are slowing down data flows and making full transparency difficult to attain today in many manufacturers. Smart machines with their own operating systems that orchestrate IIoT data and ensure data structure accuracy are being developed and sold now, making this growth constraint less of an issue. The millions of legacy industrial manufacturing systems will continue to impede IIoT realizing its full potential, however. The following graphic reflects the complexities of making an IIoT platform consistent across a manufacturing operation. Please click on the graphic to expand for easier reading.
Driven by price wars and commoditized products, manufacturers have no choice but to pursue smart, connected machinery that enables IIoT technology stacks across shop floors. The era of the smart, connected machines is here, bringing with it the need to grow services and software revenue faster than transaction-based machinery sales. Machinery manufacturers are having to rethink their business models and redefine product strategies to concentrate on operating system-like functionality at the machine level that can scale and provide a greater level of autonomy, real-time data streams that power more accurate predictive maintenance, and cross-vendor shop floor integration. Please click on the graphic for easier reading.
Machines are being re-engineered starting with software and services as the primary design goals to support new business models. Machinery manufacturers are redefining existing product lines to be more software- and services-centric. A few are attempting to launch subscription-based business models that enable them to sell advanced analytics of machinery performance to customers. The resulting IIoT revenue growth will be driven by platforms as well as software and application development and is expected to be in the range of 20 to 35%. Please click on the graphic to expand for easier reading.
Proof of concept and prototyping dominate 3D printing applications in 2019.
80% of enterprises say 3D printing is enabling them to innovate faster.
51% of enterprises are actively using 3D printing in production.
These and many other fascinating insights are from Sculpteo’s 5th edition of their popular study, The State of 3D Printing (29 pp., PDF, opt-in). The study’s methodology is based on interviews with 1,300 respondents coming from Europe (64%), United States (16.6 %) and Asia (20.2%), which is the fastest growing region internationally today as measured by this survey over five years. Eight industries are included in the research design including Industrial Goods (13.6%), High Tech (10.6%), Services (9.9%), Consumer Goods (8.6%), Health & Medical (6.2%), Automotive (5.7%), Aerospace & Defense (5.5%), and Education (4.9%). For additional details on the methodology, please see pages 6 and 7 of the study. Key takeaways from the survey include the following:
Proof of concepts and prototyping dominate 3D printing applications in 2019. Manufacturers are increasing their reliance on 3D printing as part of their broader manufacturing strategies, with production use up to 51% of all respondents from 38.7% in 2018. The following compares 2019’s purpose of 3D prints versus the last five years of survey data. Please click on the graphic to expand for easier reading.
Accelerating product development continues to be enterprises’ top focus guiding their 3D printing strategies in 2019. Mass customization and support for configure-to-order and engineer-to-order product strategies also continue to be a high priority this year, continued the trend since 2015. Increasing production flexibility is the third area of focus that guides additive manufacturing strategies today. Please click on the graphic to expand for easier reading.
Nearly 50% of enterprises say that quality control is their top challenge of using their 3D printers. As enterprises increase their adoption of 3D printing to accelerate their additive manufacturing strategies, quality is becoming increasingly more important. Manufacturers most define their success by the perceived level of quality products they deliver to their customers, which is increasing quality control as a needed benefit of 3D printing. Please click on the graphic to expand for easier reading.
Adopting a design-to-manufacturing strategy accelerates new product development and innovation, which is why CAD design leads all other activities today. When responses were asked which areas related to 3D printing and additive manufacturing, they spend the majority of their time, nearly 50% said CAD design. Building prototypes, research, and testing prototypes are also areas those enterprises adopting additive manufacturing are investing in today. Please click on the graphic to expand for easier reading.
Additive manufacturing adoption is growing across shop floors globally, evidenced by more than 70% of enterprises finding new applications for 3D printing in 2019 and 60% using CAD, simulation, and reverse engineering internally. The leading indicators of additive manufacturing becoming more pervasively adopted across global shop floors are shown in the following graphic. New uses for 3D printing, experimenting with new materials, extensive CAD Design integration combined with simulation and reverse engineering provide further evidence of how engrained additive manufacturing is becoming in production processes daily. 3D printing is now most commonly used alongside CNC machining, another strong indicator of how essential additive manufacturing is becoming to the production process. Please click on the graphic to expand for easier reading.
3D printings’ innate strengths at producing items with complex geometries at a quick pace or iteration are the leading two benefits of 3D printing in 2019. More than 40% of enterprises say that rapid iterations of prototypes and lead time reductions are the leading benefits followed by mass customization (support for configure-to-order & engineer-to-order product strategies) and cost savings. Please click on the graphic to expand for easier reading.
80% of high tech manufacturing respondents are relying on 3D printing for prototyping, leading all industries in this category. 47% use 3D printing to accelerate product development. High tech manufacturers are above average in their experimenting with new 3D printing materials and technologies, looking for greater competitive strength in their industry. Please click on the graphic to expand for easier reading.
North American-based enterprises see the scale to support complex product concepts (complex geometries), speed (quick iterations), scale (mass customizations) and cost savings as the top benefits of 3D printing. Sculpteo’s survey found that North American enterprises are more optimistic about the potential for 3D printing becoming mainstream in a production environment. While budget and physical space are the two most significant barriers enterprises face in adopting 3D printing at scale, their optimistic outlook on the technology’s future is driving greater adoption to the shop floor. Please click on the graphic to expand for easier reading.