Automation and precision: The role of smart sensors
Eric Whitley, L2L | November 12, 2023
Two key drivers of industrial advancement, automation and precision, have become the backbone of modern industry. Smart sensors are at the forefront of this technological revolution.
Smart sensors are equipped with the ability to interpret and analyze the data they collect. They come in various forms and functionalities, including temperature sensors, pressure sensors, and motion sensors, among others.
Companies that have successfully integrated these elements are not just surviving but thriving in a competitive market. Technology plays a crucial role in achieving this level of sophistication.
Smart sensors in automation
Automation has evolved significantly since the Industrial Revolution. From steam engines to assembly lines, and now to intelligent systems, automation has been a constant driver of industrial progress. We are now in an era where automation is not just mechanical but intelligent, thanks to advancements like smart sensors.
This shift has given rise to the concept of the digital factory, where interconnected technologies and smart sensors work in harmony to optimize production and efficiency.
Smart sensors are the next evolution in sensing technology. Unlike traditional sensors, which only collect data, smart sensors interpret it in real time. They have built-in computational resources, making them capable of decision-making and execution.
Smart sensors are versatile and come in various types. Temperature sensors are crucial in manufacturing processes that require heat control. Pressure sensors have various applications, from medical device manufacturing to aircraft monitoring. Motion sensors find many uses in security systems and robotics.
Organizations often integrate smart sensors into larger systems through the internet of things (IoT). They can also utilize machine learning algorithms to improve their decision-making capabilities over time, adapting to new data patterns and inputs.
Real-world applications
Ericsson has taken maritime shipping to the next level by incorporating smart sensors into vessels. These sensors monitor a range of variables, from a ship's location to the condition of the cargo. This has revolutionized the supply chain, making it more efficient and reducing the risk of cargo damage.
BJC HealthCare has implemented RFID technology to manage its inventory and supply chain more effectively. This has led to a 23% reduction in stock levels, translating to ongoing annual savings of approximately $5 million. The technology has also improved the accuracy of inventory tracking, reducing error and waste.
Volkswagen has built an Industrial Cloud using Amazon Web Services (AWS). This cloud-based system connects all of Volkswagen's machines, plants and systems across its 120+ factory sites. It allows for real-time monitoring and analysis, leading to more efficient operations and better-quality products.
Smart sensors in process enhancement
Efficiency and process optimization are essential for survival and competitiveness. Smart sensors play a pivotal role in achieving these objectives. Let's delve into the specific benefits they offer.
● Increased efficiency: Smart sensors are designed to automate an array of tasks that would otherwise require manual intervention. By doing so, they not only speed up these processes but also eliminate the possibility of human error. This dual advantage significantly enhances overall operational efficiency.
● Cost savings: The initial investment in smart sensors can be substantial, but the long-term cost-saving benefits are even more significant. By automating various processes, such as machine data collection, these sensors reduce the need for manual labor and the associated costs. Furthermore, their ability to operate with high precision minimizes waste, leading to additional savings.
● Improved safety measures: Smart sensors can be programmed to detect anomalies that could indicate potential safety hazards. This proactive approach allows companies to address issues before they escalate into serious problems, thereby enhancing workplace safety.
● Quality control: Quality control is a critical aspect of any manufacturing process. Smart sensors can continuously monitor various parameters to ensure that products meet the set quality standards. This real-time monitoring allows for immediate corrective actions, ensuring a consistent level of quality.
Challenges and considerations
While smart sensors offer many benefits, their implementation is not without challenges. These hurdles can range from technical complexities to ethical dilemmas. Let's explore these challenges in detail.
Technical challenges
Integrating smart sensors into existing systems can be a daunting task. It often requires a complete overhaul of the current infrastructure, which can be both time-consuming and costly. Additionally, the data generated by these sensors can be vast and complex, requiring robust data management solutions.
Ethical considerations
As we move toward a more connected world, issues surrounding data privacy and security become increasingly critical. Smart sensors often collect a large amount of data, some of which may be sensitive. Ensuring the privacy and security of this data is paramount.
Cost implications
While the long-term benefits of smart sensors are clear, the initial investment can be significant. Companies need to conduct a thorough cost-benefit analysis to ensure that the return on investment justifies the initial expenditure. This often involves a multi-disciplinary approach, incorporating insights from finance, operations and technology teams.
The future of sensors in process enhancement
The future of smart sensors is incredibly promising, with advancements in artificial intelligence (AI) and machine learning (ML) set to take center stage. These technologies will enable smart sensors to make more accurate and complex decisions autonomously.
Furthermore, the integration of predictive analytics will allow these sensors to anticipate issues before they occur, adding another layer of efficiency.
As technology continues to evolve, we can expect the cost of implementing smart sensors to decrease. This will make them more accessible to smaller companies, democratizing the benefits of automation and precision.
As more industries recognize the advantages of smart sensors, we can expect to see a broader range of applications, from healthcare to agriculture and beyond.
Strategic implications
Companies that invest in sensor technology gain a significant competitive advantage, positioning themselves for long-term success. This advantage comes in the form of increased efficiency, reduced costs, and enhanced quality.
While the strategic benefits of implementing smart sensors are clear, there are also tactical considerations that decision-makers must address. These include the technical challenges associated with integration and the need for specialized skills to manage these advanced systems. The data generated by smart sensors must be effectively managed and analyzed to extract actionable insights.
Conclusion
Smart sensors are playing an increasingly critical role in the advancement of automation and precision in various industries. They offer a multitude of benefits, from cost savings to improved safety and quality control.
The adoption of smart sensors is not just a technological shift — it's a paradigm shift toward a more efficient, effective and competitive future. As we look ahead, the role of smart sensors in enhancing processes will only grow, making them an integral part of the industrial landscape.
About the author
For over 30 years, Eric Whitley has been a noteworthy leader in the manufacturing space. In addition to the many publications and articles Eric has written on various manufacturing topics, you may know him from his efforts leading the Total Productive Maintenance effort at Autoliv ASP or from his involvement in the Management Certification programs at The Ohio State University, where he served as an adjunct faculty member.
After an extensive career as a reliability and business improvement consultant, Eric joined L2L, where he currently serves as the director of Smart Manufacturing. His role in this position is to help clients learn and implement L2L’s pragmatic and simple approach to corporate digital transformation.
Eric lives with his wife of 35 years in northern Utah. When Eric is not working, he can usually be found on the water with a fishing rod in his hands.