Role of IoT in Industrial Automation

Introduction: Role of IoT in Industrial Automation. The Internet of Things (IoT) has revolutionized different industries, and its impact on industrial automation is profound. IoT plays a pivotal role in manufacturing and production, optimizing processes, enhancing efficiency, and unlocking new possibilities.

A significant benefit is that connected IoT devices and sensors collect enormous amounts of data from machines and processes. This data can then be analyzed to attain valuable insights and improve decision-making.

 IoT in industrial automation results in enhanced safety and security. This is made possible by real-time monitoring and management of equipment and procedures. Organizations can identify and address threats by continuously collecting and analyzing device data.

IoT sensors can monitor environmental factors such as temperature, humidity, and gas concentration. This can help alert managers/operators to avoid accidents and protect workers.

This article delves into the multifaceted function of IoT in industrial automation, exploring key aspects such as connectivity, data analytics, and the transformative effects on the manufacturing landscape.

Role of IoT in Industrial Automation

The Role of IoT in Industrial Automation

The main goal of industrial automation is to reduce the need for people in the manufacturing process. This allows for faster production, increased safety, and better utilization of your resources and industrial analytics in manufacturing.

This goal is achieved by fully mapping the industrial process and understanding the sub-process relationships so that machines can be assigned to work and some process tasks can be automated.

Machine automation technology can be set to operate as fixed applications, programmable applications, or flexible/adaptive applications. Each of these kinds of machine automation has certain advantages and disadvantages.

Recent advances in machine automation are due to a better experience and the adoption of unique machine capabilities such as feedback controllers, robotics, networking, digital computers, and interconnectivity.


 IoT is disrupting every factor of our lives. In this new era of connectivity, IoT helps devices and machines communicate to make the environment more productive and efficient. IoT has also enabled automation in the industrial sector to a great extent and has led to greater automation in industrial processes.

This has further qualified businesses to optimize processes, resulting in resource savings and cost reductions. Also, it has helped enhance industrial processes’ safety and security.

One of the fundamental contributions of IoT to industrial automation is the establishment of seamless connectivity. IoT enables the creation of interconnected systems within a manufacturing environment by integrating sensors, actuators, and other smart devices. This connectivity facilitates real-time communication between machines, allowing for swift data exchange and coordination.

In an IoT-enabled industrial setup, machines can communicate with each other, share vital information, and respond dynamically to changing conditions. This interconnectedness lays the foundation for a more responsive and agile manufacturing ecosystem, where devices work in tandem to optimize production processes.

Data Acquisition and Analysis

IoT generates unprecedented data through the myriad of sensors embedded in industrial equipment. This data encompasses information about machine performance, production rates, energy consumption, and more. The ability to collect, process, and analyze this data is a game-changer for industrial automation.

Manufacturers can achieve valuable insights into their operations by harnessing the power of data analytics. Predictive maintenance, for instance, becomes feasible as IoT sensors continuously monitor the health of machinery, allowing for proactive interventions to prevent breakdowns. This not only decreases downtime but also extends the lifespan of equipment.

Predictive Maintenance

When devices and machines are connected and able to communicate with each other and share data in real time, a significant breakthrough is likely. It helps improve collaboration between integrated systems and processes, leading to faster and better-quality decisions.

One of the standout applications of IoT in industrial automation is predictive maintenance. Traditional maintenance practices rely on fixed schedules, leading to unnecessary downtime and resource inefficiency.

With IoT, equipment health can be monitored in real-time, and maintenance can be scheduled based on usage and performance metrics.

Predictive maintenance and how IoT has enhanced efficiency and productivity in industrial automation. Machines and devices with IoT sensors track their performance and help predict when they might break down.

This arrangement helps reduce downtime, ensures that machines continuously operate at peak performance, and enables businesses to schedule maintenance before any problems arise.

Predictive maintenance minimizes the chance of unexpected failures, optimizing the overall equipment effectiveness (OEE). This proactive approach to maintenance enhances productivity, reduces operational costs, and donates to a more sustainable and resource-efficient industrial landscape.

Supply Chain Optimization

IoT’s impact extends beyond the factory floor to encompass the entire supply chain. By integrating sensors and tracking devices, manufacturers can gain real-time visibility into the movement of raw materials, work-in-progress, and finished goods. This visibility is crucial for efficient inventory management, order fulfillment, and logistics planning.

IoT technologies can help improve supply chain administration by providing more visibility into commodities levels, shipping status, and other information. Companies can monitor the progress of the delivery of their products along the supply chain, from the factory to the end user.

Manufacturers can reduce lead times, enhance order accuracy, and minimize rubbish by optimizing the supply chain through IoT. The result is a more responsive and customer-centric approach to production, aligning manufacturing processes with market demand.

Human-Machine Collaboration

While automation is a critical driver in industrial settings, the role of human workers remains integral. IoT facilitates a harmonious collaboration between humans and machines, enhancing overall productivity. Workers can interact with intelligent machines, receive real-time feedback, and make data-driven decisions to improve efficiency.

Additionally, IoT contributes to the creation of safer working environments. Intelligent sensors can monitor environmental conditions, detect potential hazards, and alert workers to take corrective actions. This focus on safety is a crucial aspect of modern industrial automation, ensuring the well-being of workers and minimizing accidents.

Modern approaches like AI and machine learning can be integrated with IoT data to study emerging patterns and insights that would be otherwise challenging or unattainable to spot when the operations are manual. This makes businesses better equipped to predict future demand, optimize production plans based on this demand, and find fresh growth opportunities.

Challenges and Security Concerns

Despite its transformative potential, the widespread adoption of IoT in industrial automation comes with challenges. Security concerns, in particular, pose a significant hurdle.

As more devices connect to industrial networks, the risk of cyber threats increases. Manufacturers must prioritize robust cybersecurity measures to safeguard sensitive data and ensure the integrity of their automation systems.


In conclusion, the role of IoT in industrial automation is multifaceted, encompassing connectivity, data analytics, predictive maintenance, supply chain optimization, and human-machine collaboration.

Integrating intelligent technologies enhances operational efficiency and paves the way for a more sustainable and adaptive manufacturing landscape. As industries continue to embrace IoT, the synergy between automation and human ingenuity will drive innovation and redefine the future of industrial production.

IoT appliances and sensors can be set up to collect real-time data to improve quality control and inspection in industrial automation. This data is analyzed to identify any problems in the manufacturing process and ensure that the product meets the required quality conditions.

Also read: IoT and Energy Efficiency; IoT Security: Protecting Your Smart Devices; Future of Wearable in Education