What Is IoT:

IoT stands for Internet of Things. It refers to the

interconnectedness of physical devices, such as appliances and
vehicles, that are embedded with software, sensors, and
connectivity which enables these objects to connect and
exchange data. This technology allows for the collection and
sharing of data from a vast network of devices, creating
opportunities for more efficient and automated systems.
Internet of Things (IoT) is the networking of physical objects
that contain electronics embedded within their architecture in
order to communicate and sense interactions amongst each
other or with respect to the external environment. In the
upcoming years, IoT-based technology will offer advanced levels
of services and practically change the way people lead their
daily lives. Advancements in medicine, power, gene therapies,
agriculture, smart cities, and smart homes are just a very few of
the categorical examples where IoT is strongly established.
IoT is network of interconnected computing devices which
are embedded in everyday objects, enabling them to send
and receive data.
Over 9 billion ‘Things’ (physical objects) are currently connected
to the Internet, as of now. In the near future, this number is
expected to rise to a whopping 20 billion.
Main components used in IoT:
 Low-power embedded systems: Less battery
consumption, high performance are the inverse factors that
play a significant role during the design of electronic
systems.
 Sensors: Sensors are the major part of any IoT
application. It is a physical device that measures and detects
certain physical quantities and converts it into signal which
can be provided as an input to processing or control unit for
analysis purpose.
Different types of Sensors:
1. Temperature Sensors
2. Image Sensors
3. Gyro Sensors
4. Obstacle Sensors
5. RF Sensor
6. IR Sensor
7. MQ-02/05 Gas Sensor
8. LDR Sensor
9. Ultrasonic Distance Sensor
 Control Units: It is a unit of small computer on a single
integrated circuit containing microprocessor or processing
core, memory and programmable input/output
devices/peripherals. It is responsible for major processing
work of IoT devices and all logical operations are carried out
here.
 Cloud computing: Data collected through IoT devices is
massive, and this data has to be stored on a reliable storage
server. This is where cloud computing comes into play. The
data is processed and learned, giving more room for us to
discover where things like electrical faults/errors are within
the system.
 Availability of big data: We know that IoT relies heavily
on sensors, especially in real-time. As these electronic
devices spread throughout every field, their usage is going to
trigger a massive flux of big data.
 Networking connection: In order to communicate, internet
connectivity is a must, where each physical object is
represented by an IP address. However, there are only a
limited number of addresses available according to the IP
naming. Due to the growing number of devices, this naming
system will not be feasible anymore. Therefore, researchers
are looking for another alternative naming system to
represent each physical object.
There are two ways of building IoT:
1. Form a separate internet work including only physical
objects.

2. Make the Internet ever more expansive, but this requires

hard-core technologies such as rigorous cloud computing and
rapid big data storage (expensive).
In the near future, IoT will become broader and more complex in
terms of scope. It will change the world in terms of

“Anytime, anyplace, anything in connectivity.”

IoT Enablers:
 RFIDs: uses radio waves in order to electronically track the
tags attached to each physical object.
 Sensors: devices that are able to detect changes in an
environment (ex: motion detectors).
 Nanotechnology: as the name suggests, these are tiny
devices with dimensions usually less than a hundred
nanometers.
 Smart networks: (ex: mesh topology).

Working with IoT Devices:

 Collect and Transmit Data : For this purpose sensors are
widely used they are used as per requirements in different
application areas.
 Actuate device based on triggers produced by sensors or
processing devices: If certain conditions are satisfied or
according to user’s requirements if certain trigger is activated
then which action to perform that is shown by Actuator
devices.
 Receive Information: From network devices, users or
devices can take certain information also for their analysis
and processing purposes.
 Communication Assistance: Communication assistance is
the phenomenon of communication between 2 networks or
communication between 2 or more IoT devices of same or
different networks. This can be achieved by different
communication protocols like: MQTT, Constrained
Application Protocol, ZigBee, FTP, HTTP etc.

Working of IoT
Characteristics of IoT:
 Massively scalable and efficient
 IP-based addressing will no longer be suitable in the
upcoming future.
 An abundance of physical objects is present that do not use
IP, so IoT is made possible.
 Devices typically consume less power. When not in use,
they should be automatically programmed to sleep.
 A device that is connected to another device right now may
not be connected in another instant of time.
 Intermittent connectivity – IoT devices aren’t always
connected. In order to save bandwidth and battery
consumption, devices will be powered off periodically when
not in use. Otherwise, connections might turn unreliable and
thus prove to be inefficient.
 Desired Quality of any IoT Application:
 Interconnectivity
It is the basic first requirement in any IoT infrastructure.
Connectivity should be guaranteed from any devices on any
network then only devices in a network can communicate with
each other.
 Heterogeneity
There can be diversity in IoT enabled devices like different
hardware and software configuration or different network
topologies or connections, but they should connect and interact
with each other despite so much heterogeneity.
 Dynamic in nature
IoT devices should dynamically adapt themselves to the
changing surroundings like different situations and different
prefaces.
 Self-adapting and self configuring technology
For example, surveillance camera. It should be flexible to work
in different weather conditions and different light situations
(morning, afternoon, or night).
 Intelligence
Just data collection is not enough in IoT, extraction of knowledge
from the generated data is very important. For example, sensors
generate data, but that data will only be useful if it is interpreted
properly. So intelligence is one of the key characteristics in IoT.
Because data interpretation is the major part in any IoT
application because without data processing we can’t make any
insights from data. Hence, big data is also one of the most
enabling technologies in IoT field.
 Scalability
The number of elements (devices) connected to IoT zones is
increasing day by day. Therefore, an IoT setup should be
capable of handling the expansion. It can be either expand
capability in terms of processing power, storage, etc. as vertical
scaling or horizontal scaling by multiplying with easy cloning.
 Identity
Each IoT device has a unique identity (e.g., an IP address). This
identity is helpful in communication, tracking and to know status
of the things. If there is no identification then it will directly affect
security and safety of any system because without
discrimination we can’t identify with whom one network is
connected or with whom we have to communicate. So there
should be clear and appropriate discrimination technology
available between IoT networks and devices.
 Safety
Sensitive personal details of a user might be compromised when
the devices are connected to the Internet. So data security is a
major challenge. This could cause a loss to the user. Equipment
in the huge IoT network may also be at risk. Therefore,
equipment safety is also critical.
 Architecture
It should be hybrid, supporting different manufacturer’s products
to function in the IoT network.
As a quick note, IoT incorporates trillions of sensors, billions of
smart systems, and millions of applications.
Application Domains: IoT is currently found in four different
popular domains:
1) Manufacturing/Industrial business - 40.2%
2) Healthcare - 30.3%
3) Security - 7.7%
4) Retail - 8.3%
Modern Applications:
1. Smart Grids and energy saving
2. Smart cities
3. Smart homes/Home automation
4. Healthcare
5. Earthquake detection
6. Radiation detection/hazardous gas detection
7. Smartphone detection
8. Water flow monitoring
9. Traffic monitoring
10. Wearables
11. Smart door lock protection system
12. Robots and Drones
13. Healthcare and Hospitals, Telemedicine applications
14. Security
15. Biochip Transponders (For animals in farms)
16. Heart monitoring implants (Example Pacemaker, ECG real
time tracking)
Advantages of IoT:
1. Improved efficiency and automation of tasks.
2. Increased convenience and accessibility of information.
3. Better monitoring and control of devices and systems.
4. Greater ability to gather and analyze data.
5. Improved decision-making.
6. Cost savings.
Disadvantages of IoT:
1. Security concerns and potential for hacking or data
breaches.
 2. Privacy issues related to the collection and use of personal
data.
3. Dependence on technology and potential for system
failures.
4. Limited standardization and interoperability among devices.
5. Complexity and increased maintenance requirements.
6. High initial investment costs.
7. Limited battery life on some devices.
8. Concerns about job displacement due to automation.
9. Limited regulation and legal framework for IoT, which can
lead to confusion and uncertainty.

The Various Industrial

Revolutions:4 Industries That
Will Continue to Be Reshaped

by IoT in the 2020s


Internet of Things (IoT) is all anyone talks about these

days. It has managed to create a buzz that transcends all
walks of life. And its implications are far wider than
anyone can imagine. IoT is already reshaping human lives
by bringing forth a new age of integration. By extending
the power of the internet beyond smartphones and
computers, it is creating environments where information
is shared without any bounds. Now you can control the
room temperature of your Brooklyn apartment while
tanning on a Miami Beach. You can read more about How
IoT works?. It basically connects the devices to the
internet, making them controllable for humans.
But That’s Barely Scratching The Surface!!

The potential of IoT goes far beyond air quality monitors

and smart pet feeders. In the coming years, this
technology will help companies reduce costs, increase
production and offer super-unique solutions. The
competition will fuel the adaption of IoT as tech
journalist Jared Newman puts it, “And just like any
company that blissfully ignored the Internet at the turn of
the century, the ones that dismiss the Internet of Things
risk getting left behind.” The current IoT technology
trends will evolve procedures across industries. Here are
four fields that will be impacted significantly.

1. Retail

It’s generally the online side that gets the bigger slice of
attention whenever someone talks retail. Some experts
go so far as to predict the death of brick-and-mortar
establishments with brands like J.C Penney and Victoria’s
Secret closing physical stores. However, the success of
chains like Best Buy and Target tells a different story.
Turns out, people like to blend both online and in-person
shopping. In a Harvard Business Review survey, 73%
shoppers said they use multiple channels. Still, being a
more convenient option, eCommerce sites often have an
advantage over physical marts.
IoT is one thing helping brick-and-mortar stores in their
battle against their emerging online rivals. Retailers are
using this technology with a clear goal of optimizing the
customer’s shopping experience. Lowe’s has an in-store
navigation app that guides the customer’s towards their
desired products. Similarly, Sephora’s store companion
tool provides recommendations based on a buyer’s
shopping history.
IoT is also enriching physical retailers with valuable data
from in-store traffic counters, inventory tags, kiosks, and
even customer’s mobile phones. Likewise, Retailers are
using the internet of things to upgrade old marketing
tactics. Bluetooth Low Energy (BLE) is being utilized to
push information in customer’s devices as they walk
around the store. And depending on where they are,
retailers are sending coupons as an incentive for
purchase.
It wouldn’t be wrong to say that IoT has played a big role
in the evolution of coupons. What was once a tiny piece
attached to the newspaper now travels digitally based on
a person’s physical location. In the third decade of the
21st century, smart stores will be a common sight with
further innovation and ingenuity making them even more
accessible and convenient.

2. Healthcare
Before others followed its lead, the Healthcare sector was
the first to adopt IoT technology. Currently, insulin
pumps, pacemakers, and other such devices are able to
transmit data. But in the coming years, advancement in
robotics and artificial intelligence will bring good news for
millions of patients. People with impairments will soon be
able to perform everyday functions with the help of
internet-connected devices. And healthcare as a whole
will see many unprecedented improvements.
IoT has already begun to play a role in assisting people
with learning disabilities. Back in August, Vodafone
teamed up with a charity Mencap to connect living
facilities for the disabled and elderly. Both organizations
provided IoT-enabled devices to workers and residents in
order to make household tasks easier. But this is just a
glimpse of what’s to come. There has been some
research into prosthetic control system powered by IoT to
help amputees. Not to forget, exoskeletons that help
people mobility-issues will soon be available to the
general public. All signs point to a future where this
technology will transform medicine as we know it.

3. Agriculture

IoT has given birth to the concept of smart farming where

internet-enabled devices installed on a farm collect and
process crucial data. Using this data, the farmers are able
to swiftly react to any emerging issues. Smart farming is
not yet being practiced on a mass scale. However, this
could change in the coming years. Although IoT has the
potential of transforming everything from forestry to crop
growth, its biggest value to farming in near-future will be
in the form of:
 Precision Farming
 Farming Automation
As the name suggests, precision farming is all about
making farming more ‘precise’. This entails animals and
plants getting ultra-efficient treatment based on the
super-accurate data provided by machines. One thing
that differentiates precision farming from the
conventional approach is that it allows decisions to be
made on a smaller scale. It allows farmers to selectively
use pesticides and fertilizers per square meter rather
than for the entire field. Similarly, IoT is set to inspire
further farming automation. In particular, smart
greenhouses that control the climate without manual
intervention will replace traditional greenhouses
decreasing production, labor and energy costs.
Agricultural drones are already being utilized on a small
level for crop health assessment, monitoring, spraying,
field analysis, and other purposes. And this will become
more commonplace in the coming years. With drones
capturing multispectral, thermal and visual imagery from
the above, farmers will be able to make educated
decisions based on the precise data. This is how IoT will
change the work of farmers. In more than one way, IoT
will deliver a more sustainable and productive form of
farming.

4. Manufacturing

Discrete manufacturing industry spends $119 billion on

IoT solutions. This is no surprise as the internet of things
has the potential of making production procedures
virtually error-free. IoT creates an environment where
monitoring the smallest moving aspects of production is
possible. As data on the state of machinery gets
monitored and transmitted wirelessly, the chances of
performance degradation and intermittent disruptions
decrease by a great margin. Combination of cloud
technology and IoT hardware can reap the following
benefits:
 Improved Data Management
 Real-Time Maintenance
 Decrease in Expenditures
With accurate machine data in their grasp, manufacturers
can make smart decisions about sales, labor, and supply-
chain management. As data is delivered in real-time,
maintenance becomes much more strategic. The result in
reduced maintenance overhead and overtime costs. In
the future, cyber-physical systems will make the
production process and supply chain far more efficient.
Smart products will take corrective measures to avoid
damages and individual parts will be replenished
automatically. Many are dubbing this the fourth industrial
revolution after steam engines, conveyor belts and the
emergence of the internet.
The Final Words!!
The Internet of things will change everything from how
we cook breakfast to the way we drive to work. Although
how IoT will change work is a highly-debated issue as
many believe it will drive people out of jobs while others
believe it will create more. Meanwhile, there’s also this
debate surrounding the whole IoT security issue. But
regardless, the internet of things will impact multiple
industries in a profound manner. Retail, healthcare,
agriculture, and manufacturing all will become more
productive, cost-efficient and safer. Ultimately, IoT will
empower these industries to provide solutions to the likes
of which we’ve never seen before.
 Difference between IIOT and IOT



1. Industrial Internet of Things (IIOT) :

It is network of smart devices that has its own computing
capability, which are connected to form systems that
collect, monitor, exchange and analyze data at industrial
level. The main focus of the IIOT is specifically on
industrial applications such as manufacturing, power
plants, agriculture, oil & gas.
Industrial Internet of Things is a part or we can say a
subset of the Internet of Things, i.e., IIOT comes under
IOT, which mainly focuses on industrial applications.
Intelligent devices plays an important role in IIOT which
helps in communicating important information in a better
way and also to analyze and capture data in real time.
Using IIOT, business decisions can be made faster and
more accurately and it also helps to grow companies by
understanding their business process in a more better
way so that their processes become more efficient.
2. Internet of Things (IOT) :
It is all about connecting devices that have their own
unique identities, as well as network & are connected to
the Internet, embedded with sensors, electronics, &
software which allow it to collect & exchange data over
the Internet without any human interaction.
Main goal of IOT is to convert a dumb device that has no
processing capabilities, into a smarter device that has its
own computing capability so that they can exchange data
over the internet and also allowing the device to
communicate real-time data without involving a human
 being. Using IOT you can connect objects which you use
in your daily life, such as thermostats, irrigation pumps,
kitchen appliances, television to the internet. Example, A
light bulb that can be switched ON using a smartphone
application is an IoT device.

Difference between IIOT and IOT :

S.No. IIOT IOT

It focuses on general applications

It focuses on industrial applications such as
1. ranging from wearables to robots &
manufacturing, power plants, oil & gas, etc.
machines.

It uses critical equipment & devices connected over a Its implementation starts with small
network which will cause a life-threatening or other scale level so there is no need to
2.
emergency situations on failure therefore uses more worry about life-threatening
sensitive and precise sensors. situations.

3. It deals with large scale networks. It deals with small scale networks.

It can be programmed remotely i.e., offers remote on-

4. It offers easy off-site programming.
site programming.

5. It handles data ranging from medium to high. It handles very high volume of data.

6. It requires robust security to protect the data. It requires identity and privacy.
S.No. IIOT IOT

7. It needs stringent requirements. It needs moderate requirements.

8. It having very long life cycle. It having short product life cycle.

9. It has high- reliability. It is less reliable.

Difference between LoRaWAN and NB-IoT

Difference Between IoT Devices and Computers

Difference Between Cyber-Physical System(CPS) and Internet
of Things(IoT)
Components of IOT and relation with Cloud Computing
Advantages and Disadvantages of IoT
Industry 4.0 revolutions
oday’s Industry 4.0 initiatives also look to develop symbiotic and rewarding
collaborations between people and technology. When the accuracy and
speed of 4.0 tools comes together with the creativity, talent, and innovation
of your people, you get a win/win for both your workforce and your bottom
line. Your manufacturing operations become more efficient and productive,
and your teams are relieved of a lot of mundane and repetitive tasks –
giving them the opportunity to collaborate with smart technologies and
better equip themselves for the evolving technological landscape and the
AI-powered future of work.

Industry 4.0 definition

Industry 4.0 can be defined as the integration of intelligent digital
technologies into manufacturing and industrial processes. It encompasses
a set of technologies that include industrial IoT networks, AI, Big Data,
robotics, and automation. Industry 4.0 allows for smart manufacturing and
the creation of intelligent factories. It aims to enhance productivity,
efficiency, and flexibility while enabling more intelligent decision-making
and customisation in manufacturing and supply chain operations.

And any definition of Industry 4.0 would also have to include its origin from
the term Fourth Industrial Revolution. Since the 1800s, we have
experienced three industrial revolutions. They were called “revolutions”
because the innovation that drove them didn’t just slightly improve
productivity and efficiency – it completely revolutionised how goods were
produced and how work was done. We are now in the Fourth Industrial
Revolution, aka Industry 4.0.

First industrial revolution

By the early 1800s, the First Industrial Revolution was underway. The
invention of the steam engine reduced industrial reliance on animal and
human labour, ushering in a new age of manufacturing and precision
engineering.
Second industrial revolution
A century later, the growing use of petroleum and electric power meant that
machinery could be leaner and less cumbersome. The Second Industrial
Revolution was driven by the assembly line and mass production
processes, many of which are still in use today.

Third industrial revolution

Around the middle of the 20 th century, computers hit the scene. The Third
Industrial Revolution saw the early development of factory automation and
robotics. This era also saw the first use of computerized business systems
that were built to manage and analyse data.

Fourth industrial revolution

Today, manufacturing is increasingly powered by information. Vast
amounts of data come from across the business and around the world, in
real time, around the clock. AI is at the heart of the Fourth Industrial
Revolution, allowing manufacturers to not only gather all that data but use it
– to analyse, predict, understand, and report. Industry 4.0 is not
characterized by a single technology. It is defined by the seamless
integration of a number of systems, tools, and innovations.
Industry 4.0 technologies
Industry 4.0 is built on nine technology pillars. These innovations bridge the
physical and digital worlds and make smart and autonomous systems
possible. Businesses and supply chains already use some of these
advanced technologies, but the full potential of Industry 4.0 comes to life
when they’re used together.

Industry 4.0 technologies

Big Data and AI analytics: In an Industry 4.0 landscape, Big Data is

collected from a wide range of sources. Of course, this includes
 capturing data from assets, equipment, and IoT-enabled devices. Data
sources also extend outside the factory floor, into other areas of the
business and the world. They can include everything from customer
reviews and market trends that inform R&D and design, to weather and
traffic apps that help ensure smoother logistics. Analytics powered
by AI and machine learning are applied to the data in real time – and
insights are leveraged to improve decision-making and automation in
every area of manufacturing and supply chain management.

Horizontal and vertical integration: An essential framework of Industry

4.0 is horizontal and vertical integration. With horizontal integration,
processes are tightly integrated at the “field level” – on the production
floor, across multiple production facilities, and across the entire supply
chain. With vertical integration, all the layers of an organization are tied
together – and data flows freely from the shop floor to the top floor and
back down again. In other words, production is tightly integrated with
business processes like R&D, quality assurance, sales and marketing,
and other departments –reducing data and knowledge silos and
streamlining operations.

Cloud computing: Cloud computing is the “great enabler” of Industry 4.0

and digital transformation. Today’s cloud technology provides the
foundation for most advanced technologies – from AI and machine learning
to IoT integration – and gives businesses the means to innovate. The data
that fuels Industry 4.0 technologies resides in the cloud, and the cyber-
physical systems at the core of Industry 4.0 use the cloud to communicate
and coordinate in real time.

Augmented reality (AR): Augmented reality typically overlays digital

content on to a real environment. With an AR system, employees use
smart glasses or mobile devices to visualise real-time IoT data, digitalised
parts, repair or assembly instructions, training content, and more – all while
looking at a physical thing like a piece of equipment or a product. AR is still
emerging but has major implications for maintenance, service, and quality
assurance, as well as technician training and safety.

Industrial Internet of Things (IIoT): The Internet of Things (IoT) – more

specifically, the Industrial Internet of Things – is so central to Industry 4.0
that the two terms are often used interchangeably. Most physical things in
Industry 4.0 – devices, robots, machinery, equipment, products – use
sensors and RFID tags to provide real-time data about their condition,
performance, or location. This technology lets companies run smoother
supply chains, rapidly design and modify products, prevent equipment
downtime, stay on top of consumer preferences, track products and
inventory, and much more.

Additive manufacturing/3D printing: Additive manufacturing, or 3D

printing was initially used as a rapid prototyping tool but now offers a
broader range of applications, from mass customisation to distributed
manufacturing. With 3D printing, parts and products can be stored as
design files in virtual inventories and printed on demand at the point of
need – reducing both costs and the need for off-site/off-shore
manufacturing. Every year, the extent of 3D printing grows more varied,
increasingly including base filaments such as metals, high-performance
polymers, ceramics, and even biomaterials.

Autonomous robots: With Industry 4.0, a new generation of

autonomous robots is emerging. Programmed to perform tasks with
minimal human intervention, autonomous robots vary greatly in size and
function, from inventory scanning drones to autonomous mobile robots
for pick and place operations. Equipped with cutting-edge software, AI,
sensors, and machine vision, these robots are capable of performing
difficult and delicate tasks – and can recognise, analyse, and act on
information they receive from their surroundings.

Simulation/digital twins: A digital twin is a virtual simulation of a real-

world machine, product, process, or system based on IoT sensor data. This
core component of Industry 4.0 allows businesses to better understand,
analyse, and improve the performance and maintenance of industrial
systems and products. An asset operator, for example, can use a digital
twin to identify a specific malfunctioning part, predict potential issues, and
improve uptime.

Cybersecurity: With the increased connectivity and use of Big Data in

Industry 4.0, effective cybersecurity is paramount. By implementing a
Zero Trust architecture and technologies like machine learning
and blockchain, companies can automate threat detection, prevention,
and response – and minimise the risk of data breaches and production
delays across their networks.
Industry 4.0 in industrial manufacturing
Learn how to build a robust business case to benefit most from Industry
4.0.

Manufacturing 4.0
solutions in action
The digital transformation associated with Industry 4.0 brings about both
cultural and operational evolution. By unifying and connecting people, data,
and assets, you create an almost limitless range of potential optimisations.
Below are a few examples of how Industry 4.0 solutions are improving
efficiency, visibility, and sustainability in manufacturing and supply chains.

Collaborative Design Platforms: Industry 4.0 supports the creation of

collaborative design platforms where R&D teams, product designers, and
stakeholders from across your organisation can access and contribute to
design data and insights. This open approach fosters cross-functional
collaboration, idea sharing and knowledge exchange, leading to more
informed design decisions and the faster development of innovative,
customer-centric products.

Predictive maintenance: By integrating IoT sensors and data analytics,

manufacturing businesses can monitor equipment health in real-time.
Predictive maintenance algorithms identify potential failures before they
occur, allowing you to implement proactive processes which can reduce
downtime by up to 50%, and extend asset lifespan as much as 40%.

Supply chain optimisation: Industry 4.0 supports end-to-end visibility

across your global supply chain. With real-time data from suppliers,
inventory levels, production schedules, customer demand, internal teams,
and much more, you can optimise logistics, balance supply and demand,
improve order fulfilment, and enhance your overall supply chain and
manufacturing efficiency.

Agile manufacturing: AI and advanced analytics allow you to gather and

analyse real-time customer insights and feedback from sources like social
media, online reviews, and customer support interactions. Your R&D teams
and product designers can leverage this data to identify consumer
preferences, pain points, and emerging trends. By incorporating this
feedback into the design process, your teams can quickly develop products
that better align with market demands, improving satisfaction and loyalty,
and driving innovation.

Quality Control and Defect Detection: Leveraging IoT devices and

machine learning algorithms, you’ll be able to collect real-time data from all
your production lines. By continuously monitoring the manufacturing and
production process, you can detect anomalies, identify quality issues, and
take corrective actions quickly, making sure you’re always on top of product
quality.

Circular Economy Practices: Industry 4.0 supports the implementation of

circular economies, focusing on reducing waste and maximising the reuse,
refurbishment, and recycling of materials. By utilising Big Data analytics
and IoT networks, you can track product lifecycles, implement reverse
logistics for product returns, and optimise the recovery of valuable
resources. What’s more, AI-powered advanced analytics can also help your
product designers to develop products – right from the drawing board – that
are built to be more sustainable, waste fewer resources, and be more
easily recycled or repurposed.

Carbon Footprint Monitoring and Optimisation: Industry 4.0

technologies facilitate the collection and analysis of real-time data on
energy consumption, transportation emissions, and other factors
contributing to a company's carbon footprint. By accurately measuring and
monitoring emissions, you can identify areas for improvement, implement
energy-efficient measures, and develop strategies to reduce your overall
carbon footprint, helping you to meet your increasingly ambitious
sustainability goals.

Industry 4.0 benefits

summarized
Industry 4.0 represents more than simply a technology upgrade. By
knocking down silos and connecting teams and operations across your
manufacturing landscape, you begin to establish a more transparent and
holistic way of doing business – that can eventually extend across all areas
of your organisation.

Operational efficiency is enhanced with improved resource allocation,

reduced downtime, and better productivity. This efficiency extends to
sustainability initiatives where analytics and smart automations can help
you further optimise and streamline energy use, reduce waste, and even
design and innovate products that are more sustainable throughout their
lifecycle.

The fact that industry 4.0 solutions and tools let you collect, analyse, and
interpret vast amounts of data in real-time – means that you can get
actionable insights really quickly, giving you the power to make decisions
with confidence and accuracy. This applies to customers as well, because
their demands and expectations are also changing at lightning speed. So,
real-time data analytics can help you adapt quickly to personalise products,
and provide tailored solutions on demand.

We live in competitive and volatile times. Industry 4.0 tools and strategies
help improve not only efficiency and productivity, but the ability to see
around corners and gain a meaningful competitive advantage.

Introduction to Industry 4.0 and IoT:

Industry 4.0, also known as the Fourth Industrial Revolution, represents the
integration of digital technologies into manufacturing and industrial
processes.
IoT (Internet of Things) is a key enabler of Industry 4.0, as it involves
connecting physical devices and objects to the internet to collect and
exchange data.

The Role of IoT in Industry 4.0:

IoT devices, such as sensors and actuators, play a crucial role in collecting
real-time data from various points in the production process.
This data is then used for monitoring, analysis, and decision-making,
leading to improved efficiency, quality, and productivity in manufacturing.
Support Systems in Industry 4.0:
Support systems in Industry 4.0 are software and hardware solutions
designed to facilitate and enhance the adoption of Industry 4.0
technologies.
These systems provide a framework for managing and analyzing data, as
well as for controlling and optimizing industrial processes.

Key Components of Support Systems for Industry 4.0 in IoT:

Data Acquisition: IoT devices collect data from machines, products, and
environmental conditions.
Data Storage: Data is stored in cloud-based or on-premises databases for
easy access and analysis.
Data Analytics: Advanced analytics tools are used to derive insights from
the collected data, including predictive maintenance, quality control, and
process optimization.
Connectivity: Support systems ensure secure and reliable communication
between IoT devices, machines, and other components.
Cybersecurity: Robust cybersecurity measures are essential to protect
sensitive industrial data from cyber threats.
Human-Machine Interaction: User-friendly interfaces and dashboards
enable human operators to interact with and control the manufacturing
processes.
Integration: Support systems integrate with existing enterprise systems
(such as ERP) to enable seamless data flow across the organization.

Benefits of Support Systems in Industry 4.0:

Improved Efficiency: Real-time data analysis and optimization lead to

reduced downtime and energy consumption.
Quality Control: Support systems enable early detection of defects and
deviations, ensuring higher product quality.
Predictive Maintenance: IoT data helps predict when equipment will
require maintenance, reducing unplanned downtime.
Cost Reduction: Enhanced automation and process optimization result in
cost savings.
Scalability: Support systems can scale with the organization's growth and
changing needs.
Competitive Advantage: Companies adopting these systems gain a
competitive edge in the market.
Challenges and Considerations:

Data Privacy and Security: Protecting sensitive data from breaches is a

top concern.
Compatibility: Ensuring that legacy systems can integrate with Industry
4.0 support systems.
Skills and Training: Employees need training to use and maintain these
systems effectively.
Cost: Initial investments in IoT and support systems can be significant.

What is a Smart Factory?

A smart factory is a digitised manufacturing facility that uses
connected devices, machinery and production systems to
continuously collect and share data. This data is then used to
inform decisions to improve processes as well as address any
issues that may arise.

The smart manufacturing practices used by a smart factory are

enabled by a variety of technologies including artificial intelligence
(AI), big data analytics, cloud computing, and the industrial Internet of
Things (IoT).

Smart factories connect the digital and physical worlds in order to

monitor an entire production process, from supply chain management
to manufacturing tools and even the work of individual operators on
the shop floor.

Fully integrated, collaborative manufacturing systems provide a range

of benefits for operators, including allowing operations to be adaptable
and readily optimised.

Contents
Click the links below to skip to the section in the guide:
  Benefits
 The four levels
 What technologies are used in a smart factory?
 What is a smart factory in IOT?
 Key principles
 Creating a smart factory
 Cybersecurity
 Conclusion

Benefits
Smart factories use connected equipment and devices to allow for
evidence-based decision-making to optimise efficiency and
productivity throughout the manufacturing process.

Delivering an agile, iterative production process can extend the

capabilities of both devices and employees, leading to lower costs,
reduced downtimes and less waste in the manufacturing industry.

Identifying and then reducing or eliminating underused or misplaced

production capabilities increases efficiency and output with little
investment in new resources.

The benefits of digitalising a factory include those related to planning,

quality control, product development and logistics as each is assessed
and optimised based on real feedback.

There are also long term benefits to be gained through the

introduction of machine learning to the process. By collecting and
analysing data, it is possible to schedule preventive and predictive
maintenance - based on accurate real-life information - to avoid
production line shutdowns.

The Four Levels of Smart Factories

There are four levels that can be used to assess your journey through
the improvement process to becoming a smart manufacturer:
1. Level One: Basic Data Availability

At this level, a factory or facility is not really ‘smart’ at all. There is data
available but it is not easily accessed or analysed. Data analysis,
where it is done, is time consuming and can add inefficiencies to your
production process.
2. Level Two: Proactive Data Analysis

At this level, the data can be accessed in a more structured and

understandable form. The data will be centrally available and
organised with visualisation and displays assisting with its processing.
This all allows for proactive data analysis, although there will still be a
level of effort involved.
3. Level Three: Active Data

At this level, the data can be analysed with the assistance of machine
learning and artificial intelligence, creating insight without as much
human supervision. The system is more automated than at level two
and can predict key issues or anomalies to proactively predict
potential failures.
4. Level Four: Action-Oriented Data

The fourth level builds on the active nature of level three to create
solutions to issues and, in some instances, undertake action to
alleviate a problem or improve a process with no human intervention.
At this level, data is collected and analysed for issues before solutions
are generated and, where possible, actioned with very little human
input.

What Technologies are used in a Smart Factory?

Smart factories use a variety of different technologies related to the
fourth industrial revolution (Industry 4.0) to optimise smart
manufacturing processes.

These technologies include:

Sensors

Sensors on devices and machines are used at specific stages of the

manufacturing process to collect data that can be used to monitor
processes. For example, sensors can monitor temperature or other
variables and either self-correct any problems or alert staff. These
sensors can be linked to a network to provide joined-up monitoring
across several machines.
Cloud Computing

Storing and processing data collected from the sensors is achieved

through cloud computing. This if more flexible and cheaper than
traditional on-site storage, allowing large amounts of data to be
uploaded, stored, and assessed to provide feedback for decision-
making in real time.
Big Data Analytics

As more data is collected, it is possible to use it to provide insights into

how a production process is performing. Big data allows for error
patterns to be spotted and predictive quality assurance undertaken
with a greater degree of accuracy. This data can be shared between
different factories or even organisations to solve common problems
and further optimise processes.
Virtual and Augmented Reality

Augmented reality is a digital technology that involves digital

information being overlayed across reality and viewed via a
smartphone, while virtual reality is a more immersive virtual world that
requires special glasses. Both of these technologies can help smart
factory operators to organise products, production tasks and the
maintenance and repair of equipment.

Digital Twins

A digital twin can be used to represent a process or physical object

and simulate performance in the real world. This can lead to efficiency
improvements while also aiding control and operations planning.

What is a Smart Factory in IoT?

The Internet of Things (IoT) is where devices, machines and/or
processes are connected through Internet data communication
systems so that they can share information with other machines and
people.

Typically using sensor technologies and cloud computing, the

Industrial IoT (IIoT) automates a lot of the work required to track and
identify improvements in a manufacturing process.

IIoT is part of what has been termed ‘Industry 4.0’ and involves the
computerisation of many traditional industries, including manufacture.
The smart factory brings together digital and physical systems with the
Internet of Things. These systems include wireless connection,
sensors, and data collection programs.

The constant monitoring afforded by an effective IIoT-enabled

workplace will not only help reduce costs and time for production
processes, but can also improve the safety of the production
environment by monitoring for potential failure and allowing for
predictive maintenance, as well as reducing the physical demands on
workers. Using machine learning to optimise production processes
can also reduce energy consumption, offering wider environmental
benefits too.

What are the Key Principles of a Smart Factory?

The key principles behind the factory of the future are connectivity
alongside data analysis and diagnostics; leading to less shutdowns,
improved processes and optimised facilities.

A smart factory is based around using the latest technologies and

connectivity to drive improvements to processes.

Using technologies such as IoT and artificial intelligence allows for a

more responsive, yet also predictive, line; making the most of the
available resources to deliver cost-effective and efficient
manufacturing.

Creating a Smart Factory

Upgrading a factory so that is ‘smart’ can seem like it would be an
expensive exercise, but you can make fast and effective changes
without having to replace every machine in your manufacturing chain.

If you assess your manufacturing chain and pick out the most
important parts, you can quickly make changes that will benefit the
entire process. Analysing these key areas may then provide
information as to what should be improved next.

This analysis should be undertaken with a diverse team driving it,

including specialists in different areas of the business. The more you
can involve the workforce in the improvements, the more effective the
changes will be. Employees may also need training to ensure they can
use any new equipment. Indeed, rather than needing fewer people in
the workforce, the skills your employees require will change as they
monitor systems, collate data and action improvements, inspections or
repairs.
 Engineers will need to work with management and I.T. systems
specialists to find areas for upgrading, and a plan should be drawn up
to look into optimising processes, increasing sales, reducing costs and
saving time across the whole manufacturing process.

Smart Factories and Cybersecurity

Since smart factories are reliant on computing and digital systems,
cyber security needs a special mention.

Data protection and privacy are vital for any business and, as soon as
industry is digitised, cybersecurity needs to be addressed. In some
instances, industry will share data with other companies for the benefit
of everybody, for example, with safety issues. However, your
components, processes and other data need to be protected from
accidental error or even deliberate hacking.

Cybersecurity issues may create a further cost that needs to be

considered when deciding if your smart factory benefits are worth the
expense in setting up.

Summary of UNIT
Introduction to Industrial IoT (IIoT) Systems:

 Industrial IoT (IIoT) refers to the application of Internet of

Things (IoT) technologies in industrial settings.
 IIoT involves connecting various industrial devices,
machines, and systems to the internet to facilitate data
collection, analysis, and automation.
 It enables industries to make informed decisions,
optimize processes, and improve overall efficiency and
productivity.
 The Various Industrial Revolutions:

1. First Industrial Revolution (Late 18th Century):

 Transition from agrarian economies to mechanized
manufacturing.
 Steam engines and water power introduced in
factories.
 Fundamental shift from manual labor to mechanized
production.
2. Second Industrial Revolution (Late 19th Century):
 Introduction of electricity and the expansion of the
telegraph and telephone networks.
 Emergence of assembly lines and mass production
techniques.
 Significant advancements in transportation and
communication.
3. Third Industrial Revolution (Late 20th Century):
 Advent of computers, automation, and digital
technologies.
 Integration of electronics and IT into manufacturing
processes.
 The rise of the internet and globalization of
industries.
4. Industry 4.0 (Fourth Industrial Revolution):
 Current revolution characterized by the fusion of
digital, physical, and biological systems.
 Embraces technologies like IoT, AI, big data, cloud
computing, and cyber-physical systems.
 Aims to create smart, connected, and highly
efficient manufacturing environments.

Role of Internet of Things (IoT) & Industrial Internet of

Things (IIoT) in Industry:

 IoT refers to the broader concept of connecting

everyday objects to the internet.
 IIoT is a subset of IoT specifically focused on industrial
applications.
 IoT and IIoT enable real-time data collection, remote
monitoring, and automated control of industrial processes.
 They enhance operational efficiency, reduce downtime,
and support data-driven decision-making in various
industries.

Industry 4.0 Revolutions:

 Industry 4.0 represents the fourth wave of

industrialization, driven by digital transformation.
 Key technologies include IoT, AI, machine learning,
augmented reality, and data analytics.
 Goals include creating adaptive and smart
manufacturing systems and supply chains.
 It emphasizes the integration of physical and digital
realms to improve productivity and agility.

Support System for Industry 4.0:

 Support systems in Industry 4.0 provide the necessary

infrastructure and tools to implement and manage digital
technologies effectively.
 Key components include data acquisition, storage,
analytics, connectivity, cybersecurity, and human-machine
interfaces.
 These systems enable real-time data analysis, predictive
maintenance, cost reduction, and scalability.
 Integration with existing enterprise systems (such as
ERP) is essential for seamless data flow across the
organization.

Smart Factories:

 Smart factories are a central element of Industry 4.0.

 They leverage IIoT, automation, and digital technologies
to optimize manufacturing processes.
 Smart factories enable real-time monitoring of
production lines, predictive maintenance, and adaptive
production based on demand and data.
 The result is increased efficiency, reduced waste, and
improved quality in manufacturing.

These notes provide a comprehensive overview of each topic,

covering the introduction to IIoT, the historical context of
industrial revolutions, the role of IoT and IIoT in industry,
Industry 4.0, support systems, and the concept of smart
factories within the context of modern industrialization.