IoT in discrete manufacturing

Enter Industry 4.0 – the modernisation of industrial systems – with confidence. Increase operational efficiency while creating new revenue streams that keep pace with customer needs with industrial IoT from Azure.

Accelerate your path to Industry 4.0 with Azure IoT

Discover new levels of business insights and explore smart production with Azure IoT solutions for discrete manufacturing. Find solutions that support brownfield connectivity, prevent vendor lock-in and enable interoperability for industrial environments. Get best-in-class support for the duration of your factory's lifespan and IoT solutions based on open standards.

At work with industrial Internet of Things (IIoT)

Maximise operational excellence and reduce costs, while creating new revenue streams that keep you ahead of the competition. Learn more about some common uses for Azure IoT in discrete manufacturing.

Condition monitoring

Monitor key parameters of equipment to discover anomalies before they become critical issues and use this data to develop predictive maintenance programs. Connect your systems and products with sensors that gather data and relay this information to the cloud at regular intervals. Avoid premature and expensive equipment maintenance costs, extend the lifespan of your machinery and avert critical downtime with Azure IoT solution accelerator for remote monitoring.

Connected products

Improve customer engagement and operations by creating and selling products with smart components that collect product and usage data. Transform your business and generate new revenue streams by moving from a model that focuses on product sales, to one that bundles outcomes and services to the performance of connected products. Find connected products solutions with Azure IoT Central and Azure Sphere.

Facility management

Optimise energy consumption, space utilisation and workforce productivity within your factory. Create safe conditions for your employees and save money by efficiently managing key environmental controls such as heating and lighting. Simulate process outputs using a digital twin of your factory floor to optimise production output and efficiency with Azure Digital Twins.

Overall equipment efficiency

Generate critical insights of how well your plant is performing relative to its designed capacity by connecting discrete processes to sensors that enable data collection, so you can analyse this performance data and adjust your production lines. Optimise unit performance for your operations with Azure IoT solution accelerator for connected factory.

Intelligent supply chain

Create smart systems to manage complex supply chains that expand beyond the walls of your factory. Get a fully integrated view that includes business planning, demand forecasting and track-and-trace monitoring to minimise losses. Build a smarter supply chain with Azure IoT solution accelerator for connected factory, Azure Sphere, Azure Blockchain and Azure Maps.

Asset tracking

Avoid expensive equipment loss, minimise operational downtime and enhance the productivity of your first-line workers. Tag your assets, equipment and tools that are used throughout multiple locations with Azure IoT solution accelerator for remote monitoring.

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Azure IoT solution accelerator demo: Connected factory

Learn how the Azure IoT solution accelerator for connected factory is used to connect existing factory equipment and machinery from multiple production lines and locations. See how brownfield connectors and the OPC UA framework is used to standardise data and communication to the cloud.

Global view

Factory view

Production line view

Machine view

Issue resolution

Step 1 of 4

Global overview

The global summary dashboard provides operators with an overall picture of their manufacturing business.

Step 2 of 4

Critical reporting

At a glance, operators can see the status of their facilities, including performance, efficiency and output.

Step 3 of 4

Alert logging

Critical alerts, outages or operational and efficiency anomalies are all escalated for fast resolution.

Step 4 of 4

Alert escalation

There is a critical alert at a facility in Germany, let’s take a closer look…

Step 1 of 3

Factory-level KPIs

At an individual factory level, KPIs and alerts are summarised for this particular location.

Step 2 of 3

Production details

Each production line can be individually represented, monitored and analysed. Efficiency and production output are also summarised in near real time to pinpoint a problem.

Step 3 of 3

Critical alerts

We can see that the critical alert for this facility is regarding Production Line 6, making car parts. Let’s dig deeper…

Step 1 of 3

Production line view

At this level, the specific production line is summarised, providing production data, machine run times and actual device data metrics.

Step 2 of 3

Specific machine analysis

The specific part can now be identified as having a fault or anomaly. We can see that the robotic arm on this line is where the problem is.

Step 3 of 3

Targeted alerts

There are several warnings and escalations for this site but only one that is critical. The alert for this device is to do with temperature. Let’s click through and see what might be the issue with this arm.

Step 1 of 4

Machine view

At the machine level, raw device data, performance and even predictive analytics can be displayed.

Step 2 of 4

Deep-dive analytics

Here, the actual device metrics and values can be displayed in near real time. The device-specific KPIs, run times and remaining scheduled requirements are also displayed.

Step 3 of 4

Contextual decision-making

We can see that the device should be available for us for quite some time but the dashboard predicts that we will have an unscheduled failure much sooner.

Step 4 of 4

Take action

Here, the operator can select the critical alert to take action.

Step 1 of 2

Address the issue

The alert panel provides near real time data, as well as historical information. The data visualisation clearly shows the breached threshold and the need for action before the part fails, potentially halting production.

Step 2 of 2

Business integration

A technician can be called to the site through Dynamics365 and Field Service integration. The maintenance can be scheduled at a convenient time, between shifts, to minimise impact on production schedules.

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