Development and implementation of IOT-based systems for monitoring and digitalization in pursuit of a smart manufacturing approach

Abstract

Industry 4.0 has introduced a new way of using technology within manufacturing processes, generating new opportunities for optimization and efficiency. This digital transformation allows companies to increase productivity through automation and system integration and facilitates better decision-making based on accurate, real-time data and metrics. Furthermore, embracing this new technological era allows customized production and ongoing process improvement. Currently, many solutions based on cutting-edge technologies are costly, complex to implement in legacy systems, and lack compatibility in conventional manufacturing environments, making it difficult for SMEs to adopt such systems and compete with larger companies with more complex systems. Implementing innovative and Industry 4.0-based technologies does not necessarily have to be expensive and inflexible. This project seeks to design and integrate low-cost systems that can be implemented in conventional work environments for real-time environmental variable monitoring outside machines. It also aims to implement sensors and digitization processes for legacy machines to give them a second life and enhance performance. To achieve this, a balance must be found between the components used and their ability to accomplish the task, making it essential to understand how to integrate them. Thus, the proposed methodology involves using simple yet powerful sensors, adaptable programming, low-cost microcontrollers capable of connecting and sending information to the cloud, and real-time data visualization tools. This work gathered information from various SMEs about current opportunities and needs and how our systems can facilitate change. The outcome of the systems development provides a comprehensive pair of solutions that offer capabilities for real-time monitoring, digitization, trend analysis and information, physical test validation, and the implementation of cloud solutions.