IIoT Monitoring in Industry 5.0: Key KPIs, Successful Implementation, and Practical Solutions for Smart Production

Industrial production is at a significant turning point. With advancing digitalisation and the introduction of Industry 5.0, the focus is on new technologies and concepts aimed at optimising the efficiency, flexibility, and sustainability of production processes. In this context, IIoT monitoring (Industrial Internet of Things) plays a central role. It connects machines, people, and data within an intelligent network, enabling companies to make well-informed decisions in real time. This article explores the connection between IIoT monitoring and Industry 5.0, highlights key KPIs, and explains how businesses can successfully implement an IIoT monitoring platform.

Industry 5.0 and IIoT Monitoring: A Powerful Duo

Industry 5.0 puts people back at the centre of production and promotes collaboration between human and machine. While Industry 4.0 was mainly characterised by automation and networking, Industry 5.0 expands these concepts to include the human factor. IIoT monitoring plays a decisive role here. It enables the continuous monitoring and analysis of production processes, which not only increases efficiency but also improves collaboration between man and machine.

Industry 5.0 emphasises the role of people in production by not only promoting collaboration between man and machine, but also by specifically integrating the individual skills and expertise of employees into the processes. In this new era, the aim is to combine the strengths of automation and artificial intelligence with the creativity, flexibility, and problem-solving expertise of mankind.

While Industry 4.0 focused on automation, what often led to a reduction in manual intervention, Industry 5.0 recognises the added value that humans offer in complex and unpredictable situations. Machines can analyse huge amounts of data and perform repetitive tasks efficiently, but it is people who use their experience and judgement to find innovative solutions and continuously improve processes.

IIoT monitoring plays a key role in this context as it provides humans with the relevant information and tools to make informed decisions. It enables a human-machine symbiosis in which people are not only monitored but are actively involved in the production process and can use data-supported findings to control and optimise their work in a targeted manner. By integrating IIoT monitoring into Industry 5.0, companies can monitor the condition of their machines in real time and react to deviations or potential problems at an early stage. This is crucial to increase the flexibility and adaptability of production while maintaining quality and efficiency at a high level.

The Importance of KPIs in Industry

Monitoring and analysing key performance indicators (KPIs) is an essential part of IIoT monitoring and a central aspect of Industry 5.0. Important KPIs in modern industrial production include overall equipment effectiveness (OEE), which maps machine efficiency and product quality on a comprehensive scale. OEE is made up of the components availability, performance, and quality and serves as an indicator of the productivity of machines or production lines. Continuous monitoring of OEE through IIoT monitoring can identify flaws and highlight potential for optimisation.

Another important KPI is machine availability, which measures the proportion of time a machine is in productive use. High availability indicates well-maintained and reliable facilities, which in turn increases productivity. The throughput, which measures the quantity of units produced in a given period, is also a key indicator of production efficiency.

In addition, monitoring first pass yield (FPY) plays an important role. The FPY indicates the proportion of products that fulfil the quality requirements in the first production run without rework. A high FPY value indicates stable and efficient production processes. In view of the increasing pressure to produce more sustainably, monitoring energy consumption is also becoming an increasingly important KPI. Companies that continuously monitor their energy consumption can not only improve their environmental balance, but also reduce their energy costs.

The Implementation of IIoT Monitoring Platforms

The introduction of an IIoT monitoring platform requires careful planning and implementation. Companies must first consider how best to connect their machines to the IIoT platform. For older machines that are not inherently IIoT-capable, retrofit solutions offer a cost-effective way to connect them retrospectively. Sensors and communication modules are attached to the machines, which record the relevant data and transmit them to the IIoT platform. Plug-and-play systems are ideal for new machines that are already designed for integration into IIoT platforms. These enable quick and easy connection without the need for extensive configuration. In addition, smart kits offer a flexible way to integrate different types of machines into an IIoT platform. These kits contain pre-configured hardware and software solutions that enable rapid implementation.

When selecting the right IIoT monitoring tool, companies should pay attention to several important criteria. One central requirement is the scalability of the platform. It should be able to keep pace with the company's growing requirements, especially if production is expanded or diversified. The user-friendliness of the platform also plays an important role. An intuitive user interface and simple operation are crucial for employees to be able to use the system efficiently. This reduces training times and increases acceptance. The interoperability of the platform must also be guaranteed. It should be able to be seamlessly integrated into existing systems such as ERP, MES or SCADA so that all relevant data can be merged and comprehensively analysed. Finally, data security must not be neglected. The platform should support modern security standards such as data encryption and access controls to protect sensitive production data. Another important criterion is real-time data processing. To be able to react quickly to changes in production, the platform should record and process data in real time. This enables companies to react immediately to disruptions or deviations and thus ensure the efficiency and quality of their production.

Successful Implementation and Continuous Optimisation

The introduction of an IIoT monitoring platform is only the first step on the road to Industry 5.0. Companies must ensure that they continuously utilise the data obtained to improve their production processes. This requires close collaboration between IT and production teams as well as regular training and further education for employees.

Conclusion:

Industry 5.0 represents the next evolutionary stage of industrial production and requires close collaboration between man and machine. IIoT monitoring plays a crucial role in this by enabling continuous monitoring and optimisation of production processes. Selecting the right KPIs and implementing a suitable IIoT monitoring platform are decisive factors for success. Companies that follow this path can not only increase their efficiency and flexibility, but also act as pioneers in modern industrial production.

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ProCom Automation GmbH

by: Sergej Gigel - Senior Sales Manager - ProCom Automation GmbH