Revolutionising Industrial Manufacturing: The Convergence of IoT and Smart Engineering

Revolutionising Industrial Manufacturing: The Convergence of IoT and Smart Engineering

The Industrial Internet of Things (IIoT) is the convergence of IoT and industrial manufacturing that sees the utilisation of big data, machine-to-machine communication, and Machine Learning (ML) to improve the efficiency and reliability of industrial plants. In the current year, reports share the IIoT market is valued at 865 billion, with forecasts suggesting exponential growth of up to 33.3 trillion by 2030, highlighting the push towards smart factories and Industry 4.0. IIoT is capable of supporting an array of industrial applications, from software defined production processes to robotics, analysing and exchanging data to deliver the insights that IIoT equipment needs to perform.

Below, we will look at how IoT and software engineering are used to establish functioning smart factories, then explore the workings of Industry 4.0 and the challenges and solutions of IIoT.

Smart Factories

In practice, ‘smart factories’ utilise the Internet of Things and implement it within the machinery and equipment of an operation and supply chain, turning the traditional manufacturing environment into a network of interconnected machines and business, as smart factories, improves and enables the dynamics of the production and business. Every sensor of every device or piece of equipment is linked to create a continual flow of real time data that can be leveraged by the machinery, effectively producing an active and cohesive ecosystem that can optimise every aspect of the manufacturing process.

Once a smart factory is optimised, dramatic improvements in efficiency and significant reductions in equipment downtime can be achieved through the collection and analysis of relevant data. Maintenance needs and production changes become predictable as the IIoT system consistently responds to new information, generating impressive leaps in production quality and operational success.

Coupled with the concept of Software Defined Vehicles (SDVs), the Industrial Internet of Things (IIoT) represents a powerful tool for enhancing various aspects of automotive production and operational efficiency. From automotive manufacturers detecting and addressing equipment issues before they cause stoppages, to food and beverage companies optimizing their supply chains for freshness and speed, IIoT has the potential to improve almost any aspect of a business’s production and efficiency. Moreover, even medical devices contribute to this paradigm shift, utilizing IIoT for monitoring, analysing, and exchanging data to deliver the insights necessary for optimal performance. Furthermore, the integration of digital twins and early prototyping within a simulated environment further exemplifies this potential, saving valuable time and costs in the final automotive production installation


The Role of Software Engineering

Software engineers like our very own at Mobica work diligently to help businesses develop IoT solution, working with them to create reliable and secure systems that meet stringent industry standards. Software engineering plays a critical role behind the scenes of any IoT system, from the sensors of each piece of machinery that gather data, to the cloud computing software that enables the machines of a smart factory to not only communicate, but also make the decisions that have seen the paradigm shift into Industry 4.0, pushing the boundaries of what is possible in modern manufacturing.

Industry 4.0

Industry 4.0 has seen a comprehensive integration of digital tech into the manufacturing process with the aim of increasing efficiency and autonomy in production, while reducing the downtime of machinery and syncing equipment for plant flexibility. Below we will look at some of the most vital parts that software engineering brings to the IIoT network.

  • IoT and Industry 4.0: While we have touched on it, IoT is essential for creating the interconnected and intelligent factories that are central to Industry 4.0 and IIoT, as IoT devices collect data from machines and equipment on the production floor which is then used to monitor, analyse, and optimise manufacturing processes.
  • Data and Connectivity: IIoT then provides the infrastructure for smart factories to collect enormous amounts of data from the industrial environment through webs of machinery sensors and actuators. Industry 4.0 leverages this data to drive the intelligent automation and decision making of its equipment. 
  • Digital Twins: In a modern factory, the concept of digital twins, or virtual replicas of physical systems, are utilised for simulations and equipment analysis, and can be used to model entire manufacturing processes or a single product or HW devices.


  •   Smart Manufacturing: As IIoT solutions continue to provide the foundation for integrating technology into manufacturing, we are witnessing a shift towards fully automated factories. Continuous innovation in this area suggests that in the future, these smart factories may require minimal human intervention.

    Challenges and Solutions in IIoT

    The integration of IoT into industrial manufacturing has numerous obstacles that require attention, especially considering a transition period where older equipment that may not be integrated with other systems is working alongside modern tech. Manufacturers also have security to consider, as well as ensuring different systems can work and integrate data together, which leads to the necessity of finding people with the right tech talent to help in development.

    Encryption and security threat detection has become a significant point of focus in recent years due to the sheer amount of data that is sent and received from hot spots like smart factories, and without proper encryption and access management and other deterrents, IoT sensors can be at risk from cyber-attacks.

    To ensure data can safely integrate, software engineers are tasked with developing robust inoperability frameworks that can facilitate seamless interactions between devices and systems, irrespective of their proprietary origins. It comes down to creating a common language or set of rules that all the devices of a smart factory can follow, granting them the ability to share information and perform.

    For manufacturers looking to implement IIoT into their factories, these challenges will need to be addressed if companies want safe and seamless operations, fortunately, for those willing to invest in the correct tech or engineering services, they have a clear path forward to transforming their operations.

    Parting Thoughts

    With smart factories and the utilisation of IIoT becoming the norm in modern manufacturing setups, more and more businesses will be moving to optimise their processes in ways that were unimaginable just a decade ago. The shift from traditional to smart, while complex, has the potential to bring immense rewards to those who are willing to invest and upgrade in both technology and machinery, bringing with it streamlined operations, predictive maintenance, and an improved ability to meet market demands.

    Achieve Your Tech Ambitions with Mobica Talent

    Mobica software services cover the entire tech stack. We can assist with additional development expertise to launch a new IoT project, or offer ongoing support to complete one. Our Talent-as-a-Service (TaaS) is available with the knowledge to meet your needs, from mobile POS to Software Defined Vehicles and more, our Mobicans have the talent to help you reach your tech ambitions.

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