IoT in Mining: 5 Ways IoT is Driving the Connected Mine

IoT in Mining

BehrTech Blog

IoT in Mining: 5 Ways IoT is Driving the Connected Mine

Driven by intensifying challenges of the volatile commodity market, declining ore grades, rising energy costs and extreme operating conditions, the ability to leverage reliable and flexible communication systems is growing in importance. Leading mine operations have already started on a digital transformation, as they look to create the ‘Connected Mine.’ Building on the necessary communications required for everyday workings of the mine with layers of applications and systems leveraging massive scale IoT sensor networks, the future of mining is certainly safer, smarter and far more productive. In fact, the World Economic Forum forecasts that $425 billion of value will be added to the industry over the next five years through digitalization.

Here are 5 ways IoT in mining can improve safety, ensure efficient loads, reduce operational delays and provide real-time data for intelligent decision-making.

1. Asset Tracking, Remote Diagnostics & Predictive Maintenance

As an asset-intensive industry, mining entails a wide-array of equipment from drills, excavators, diggers and conveyors to pumps, motors and fans, which are widely dispersed both above and underground. Wireless IoT sensors that monitor and track critical asset parameters such as pressure, vibration, flow rate and temperature as well as engine telemetry boxes, enable real-time remote diagnostics, troubleshooting and asset tracking across the entire mine. In combination with analytical models, corrective maintenance and procurement of spare parts can be effectively planned to prevent asset downtime and help companies stay ahead of expensive production losses.

2. Emission and Groundwater Level Monitoring

Diesel exhaust emitted from underground excavating equipment and drilling machines contain toxic gases and fine particles that present serious health risks. With the adoption of stationary and mobile gas detectors, as well as particle sensors, emission levels and threshold limit values can be effectively controlled to sustain a secure working environment that complies with safety standards.

Chemical residues from mining operations threaten to contaminate groundwater and incur serious environmental issues. With data from level sensors, mining operators can keep track of real-time changes in groundwater levels at mine shafts, especially during rainfalls. Timely and effective pumping can be performed to prevent excessive inflows, thus avoiding contamination and underground flooding.

3. After-blast Monitoring

Following a blast to open up a new site within the mine, the area is often filled with toxic fumes and debris. Waiting hours to ensure blast fumes completely clear out can lead to costly operational downtime. Having a wireless environmental monitoring system in place, operators and miners can stay informed when an area is safe enough to resume work. Unnecessary wait times can be cut down, thereby enabling a faster turnaround after blasts and increasing productivity.

4. Wearable-based Event Reporting & Rock Bolt Monitoring

As mines are renowned to be among the most dangerous working environments with high risk of explosions, equipment accidents and toxic exposure, ensuring miners’ health and safety has always remained a big challenge. With the help of IoT wearables, miners’ health status and working environment (i.e. temperature, humidity, radiation, noise and gas levels) can now be tracked in real-time. Managers are immediately notified of fatigue, exhaustion, and “out-of-tolerance” incidents experienced by their workers, while miners will receive timely warnings in the event of potential hazards. Similarly, sensors monitoring seismic activities in underground mines can be installed on rock bolts to effectively assess their integrity and reduce fatal risk of ground falls.

5. Ventilation-on-Demand (VoD)

Ventilation can account for 30-40% of energy consumption in underground mines. Supporting implementation of VoD systems, IoT sensors can be leveraged to constantly monitor air quality and air flows at different areas in the mine for remote adjustment of the fan speed. Transmitting data from occupancy sensors or worker registration data from NFC tags also ensures that ventilation is activated in work zones where miners are present. This results in significant energy savings, thereby remarkably reducing operational costs and environmental footprint.

Wireless Connectivity for the Connected Mine

While connectivity is key to harvesting large-scale data in the “connected mine,” remote location, extreme depths, confined spaces, and non-symmetric mine topology introduce the most hostile condition for data communication. Wired networks have limited range, are expensive and highly vulnerable to the physical impact caused by in-pit operations of mining equipment. Cellular and short-range solutions such as Wi-Fi fail to deliver sufficient coverage and reliable signals in underground and hard-to-reach sprawling mines.

Geared for low-bandwidth, low computing end nodes, third-generation Low Power Wide Area Networks (LPWAN) offer highly power-efficient and affordable IoT connectivity in complex and remote industrial environments. No current wireless classes can beat LPWAN when it comes to battery life, device and connectivity costs, and ease of implementation. As the name implies, LPWAN nodes are designed to operate on independent batteries for years, rather than days as with other wireless solutions. They can also transmit over many kilometers while providing deep penetration capability to connect devices at hard-to-reach indoor and underground locations, making it the ideal technology for enabling IoT in mining.

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LPWAN and Bluetooth Low Energy: A Match Made in Networking Heaven

LPWAN and Bluetooth

BehrTech Blog

LPWAN and Bluetooth Low Energy: A Match Made in Networking Heaven

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Given its significant benefits in terms of reliability, minimal latency and security, wired communications has been the backbone of industrial control and automation systems. Nevertheless, as the new wave of IoT applications arises, we quickly see wired solutions reaching their limits.

Trenching cables is inherently cumbersome, capital- and labor-intensive, not to mention the fact that damage to wiring brings the risk of production downtime. Due to the plethora of proprietary wiring protocols, any additions or modifications to the architecture is deemed costly and could even entail a “rip-and-replace” of cables and conduits. The bulky and expensive wired infrastructure thus limits the number of connected endpoints and is highly constrained in terms of range and network capacity.

In direct comparison, wireless networks require far fewer hardware components, and less installation and maintenance costs. As there aren’t any physical cables involved, sensors can be easily attached to mobile assets to tap into a new host of operational data. On top of that, wireless networks make data collection in hard-to-access and hazardous environments possible and can flexibly expand to meet your changing business needs.

The central value around IoT is the unprecedented visibility into existing processes, equipment and production environment that empowers strategic decision-making. Think of applications used for asset maintenance, facility management and worker safety. As opposed to high-bandwidth, time-sensitive communications, many IoT sensor networks send small-sized telemetry data periodically or only when abnormalities are identified. Of even greater importance is their ability to connect vast numbers of distributed field assets and devices to bring granular business insights. With this in mind, wireless connectivity is often the better option to bring your physical “things” online.

Given the bewildering range of wireless solutions available in the market today, choosing the right technology is no easy task. Not all wireless technologies are created equal and not all can manage every use case. For this reason, there is a growing demand in multiprotocol support. Devices that combine the complementary strengths of different wireless standards and frequencies in one design, such as LPWAN and Bluetooth, makes it feasible for more complex sensor networks to exist.

LPWAN and Bluetooth Low Energy: A Match Made in Networking Heaven

Bluetooth’s ubiquity and global, multi-vendor interoperability has made it the core short-range technology for industrial and commercial IoT projects. Bluetooth Low-Energy (BLE) enabled devices are often used in conjunction with electronic devices, typically smartphones that serve as a hub for transferring data to the cloud. Nowadays, BLE is widely integrated into fitness and medical wearables (e.g. smartwatches, glucose meters, pulse oximeters, etc.) as well as Smart Home devices (e.g. door locks), where data is conveniently communicated to and visualized on smartphones. The release of the Bluetooth Mesh specification in 2017 aimed to enable a more scalable deployment of BLE devices, particularly in retail contexts. Providing versatile indoor localization features, BLE beacon networks have been used to unlock new service innovations like in-store navigation, personalized promotions, and content delivery.

The challenge with BLE-enabled devices is that they must have a way to reliably transmit data over a distance. The reliance on traditional telecommunications infrastructure like Wi-Fi or cellular has put growth limitations on these sensor networks. Long range communication is often a significant obstacle in industrial settings because Wi-Fi and cellular networks are not always available or reliable where industrial facilitates or equipment are located. This is why a complementary, long-range technology is so important.

Geared for low-bandwidth, low computing end nodes, the newer LPWAN solutions offer highly power-efficient and affordable IoT connectivity in vast, structurally dense environments. No current wireless classes can beat LPWAN when it comes to battery life, device and connectivity costs, and ease of implementation. As the name implies, LPWAN nodes are designed to operate on independent batteries for years, rather than days as with other wireless solutions. They can also transmit over many miles while providing deep penetration capability to connect devices at hard-to-reach indoor and underground locations.

In this context, LPWAN extends the power efficient and high data rate capabilities of BLE devices by serving as a reliable and robust backhaul for long range communication in both complex indoor environments and remote locations. This increases deployment flexibility, reduces the need for costly and complex network infrastructure requirements and makes it more feasible for massive-scale sensor networks to exist.

You Might Also Like : Introducing the new mioty BLE Dual Stack

 

For example, LPWAN and Bluetooth Low Energy together, enable the deployment of IoT networks in a significantly broader geographic area. This flexibility is increasingly important as more IoT sensor networks are deployed in far flung, industrial locations like remote mining, oil and gas and manufacturing facilities.

Together, they also cost-effectively enable critical indoor applications like asset tracking and consumables monitoring that require reliable connectivity for a vast number of end-nodes. The physical barriers and obstructions as well as co-channel interference with other systems often present in indoor environments can create challenges for reliable data communication. However, the long-range, deep indoor penetration and high interference immunity offered by next-gen LPWAN technologies ensures reliable data connection in any large industrial campuses or smart buildings.

Wrapping Up

The success of any IoT deployment is dependent on reliable connectivity, which remains a huge obstacle for numerous industries like mining, manufacturing, oil gas and smart buildings. These industries are faced with complex and often remote environments where traditional wired and wireless connectivity options are not possible as standalone technologies. That’s why combining different technologies that cover each other’s drawbacks while also adding on top their individual advantages is critical for building a reliable and robust IoT network. The combination of LPWAN and Bluetooth Low Energy in one design, increases flexibility and integration and opens up a new world of exciting industrial and commercial applications. 

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The Importance of Data Interoperability: 8 Experts Weigh In

Data Interoperability

The Importance of Data Interoperability: 8 Experts Weigh In

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Across all industries, maintaining a competitive advantage requires more than simply finding ways to optimize operations and reduce costs. It’s about being smarter. The chief motivation for adopting IoT technologies is the interconnection of critical data from disparate systems and processes to make more informed and intelligent business decisions.

This week on the blog we’ve asked 8 experts to weigh in on the importance of data interoperability in their industry.

Adam Belnap, VP of Sales & Customer Relations

Data interoperability is extremely important for one simple purpose: growth. The fusion of multiple data points brings huge value for operational insight, power to make educated decisions and to create shared workflows for improved efficiency. Companies that view all of their data as a complete resource for growth, will scale quicker and have a faster ROI on multiple areas of their business.  

Matt Schaubroeck, CEO

There are a number of systems that exist in buildings, and unless we can understand how each of these systems affects the other, we won’t be able to unlock that building’s true potential. Data is only helpful if you are able to use it properly – an interoperable dataset helps to increase the value of that data between multiple systems, the sum of which is greater than each of its parts. That interoperability also helps identify trends in the data that may not have been evident through a single system – multi-variable data analysis can unlock new insights that we are not yet aware of. Any data collection system should take steps to ensure that their information can be easily shared, while maintaining user confidentiality, security and anonymity. That balance between data confidentiality and interoperability will unlock new insights for data-driven solutions, both in buildings and across a wide variety of industries.

Data interoperability in general and between systems is one of the most important must-haves for IoT ecosystems. Without it, exchange, as well as consumption of data with a clear explanation of content, context and meaning, is challenging. This has a major impact on IoT ecosystem providers and end-users. If data interoperability is not sufficient, it will hinder the provider and end-user from reaping all of the benefits that IoT has to offer. It is the foundation of data exchange and data-based decision-making.

Before the time of OMS, meter data was formatted and transmitted in a company-specific way. Thus, there were different protocols and each company had its own formatting. For utilities, this represented a major effort to decode the meter data and bring it to billing. With the introduction of OMS, utilities can now process meter data from a wide variety of meter providers in the same way every time.

In the process of digitalization, this is more necessary than ever, because now the meter data can come to one platform via the most diverse transmission protocols. There, they must be able to be processed in the simplest way. This is only possible if there is a specification that defines the data format.

In this context, there are efforts towards OMS over LPWAN, GSM or Bluetooth. Only the adoption of a specification and standard will lead to the success of these technologies. This also needs to exist in data processing.

Nathan Mah, Cofounder

Data interoperability is a topic that forward-thinking properties are engaging in. In order to fully understand your data and how it can interact together, you must first choose the data sources you need to operate your business efficiently as well as be able to build the foundation of open vendors and integrations. Architecting vendor solutions around a data interoperability strategy is a critical component of any smart building portfolio, but some enterprises are further along in the conversation than others. 

Commercial buildings represent the perfect site of ideal data interoperability; they are physically and geographically finite, the use cases can be tied directly to ROI, and there are not yet extensive regulatory or government requirements to consider when developing a data interoperability strategy. In the future, we expect a “blueprint” of vendors who have well defined data interoperability and share data openly to gain traction in the market as smart buildings continue to scale. Leveraging various sources of data to targeted use cases for buildings, managers, and tenants will increase the overall customer experience and lead to an improved future for all.

Data interoperability via sensors can offer unique insights into the correlated systems. Interoperability shows us how much we can gain when aggregating larger pools of data, such as broader insights, which can allow the user to make broader decisions on informed data. In addition, there is a chance for indirect analysis or insights gained from an unrelated use case. 

Data interoperability is what enables IoT applications to be useful. Data and the decisions that are derived from that data are not isolated to IoT systems. The contents and context of data and what the data analytics provides to the rest of the business is even more important. An IoT application is not an end to a mean. It’s a decision that, paired with other support, enables an organization to actualize broader company strategies from intelligent data sources.

Interoperability of sensors, machines and data services is the key to high user-friendliness and smooth deployment of IoT technologies. Unfortunately, in agricultural applications there is still a very heterogeneous and historically grown system landscape. At Agvolution, we therefore focus on the open and flexible exchange of data. Our IoT technology in particular uses mioty and other open wireless IoT protocols to provide the perfect user experience.

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Smart Brownfield: Bringing IoT Connectivity to Legacy Industrial Sensors with LPWAN

Industrial sensors

BehrTech Blog

“Smart Brownfield:” Bringing IoT Connectivity to Legacy Industrial Sensors with LPWAN

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Industries around the world are undergoing a major digital transformation. According to a new market research report, the Industrial IoT (IIoT) market will be worth $110.6 billion by 2025. From manufacturing and logistics, to oil and gas and agriculture, IoT provides undeniable benefits and opportunities for optimization, efficiency, asset management and industrial control.

As optimistic as it sounds, the realization of IoT initiatives is inherently challenging. One of the biggest obstacles is found right where IoT starts – gathering operational data at the edge and communicating it to the cloud.

Most legacy assets, machines and equipment were not designed to connect beyond industrial facilities, creating huge data silos across the organization. This leaves companies with two choices: building entirely new, greenfield plants with new IoT technologies or updating brownfield facilities for IoT connectivity. Since a substantial upfront investment makes a “rip-and-replace” approach to industrial IoT mostly infeasible, the demand for gathering data from legacy industrial sensors and systems such as 4-20mA sensors, will continue to rise.

The 4-20mA Challenge

The 4-20mA current loop is a widely adopted and versatile analog signalling standard found in brownfield industrial sensors. Today’s 4-20mA sensors can track a variety of variables, including temperature, pressure, humidity, and water levels. In a current loop, these process variables are gathered by the sensors and then converted into a proportional current value between 4 and 20mA. Traditionally, these signals are then sent to the process controller via wiring to trigger responses on actuators. For example, a 4-20mA current loop configured to measure tank water levels might assign an empty tank a value of 4 milliamps and a full tank a value of 20 milliamps. In this case, an electrical current of 12 milliamps would imply the water tank is half full. Likewise, from a temperature perspective, operators could assign 4 milliamps to 0 degrees Celsius and 20 milliamps to 100 degrees Celsius in which case 10 milliamps would translate to 37.5 degrees Celsius. Readings below or above these thresholds would signal to operators that there is a temperature issue.

While 4-20mA current loops are versatile and simple to configure for process controls, they also pose a significant challenge. Data flows from these industrial sensors operate within a closed-loop and stay locked on the factory floor. This creates huge data silos across the organization and prevents users from obtaining a comprehensive picture of what’s happening with their equipment, processes and facilities. Furthermore, in many cases 420-mA networks require complex wiring to transmit the output signal to a receiving device, such as a distributed control system, a programmable control system, a data acquisition system, a recorder, or an indicator. In many indoor and outdoor industrial environments, running cables is complex, cumbersome and expensive.

Creating a “Smart Brownfield” with LPWAN

The concerted effort in gathering data from legacy industrial sensors and systems will become a top priority in 2021 and beyond. 4-20mA sensors are, and continue to be, widely used in enclosed industrial networks to measure and report critical variables to a local controller for automation and control tasks. As such, a retrofit IoT solution that adds robust, scalable and long-range IoT connectivity to 4-20 mA devices will open immense possibilities for better operational oversight and planning, especially when it comes to remote assets and systems.

In particular, plug-and-play low-power wide area network (LPWAN) connectivity solutions are easing IoT integration with legacy equipment. For example, an IoT wireless transmitter embedded with 4-20 mA interfaces can draw process data from field sensors and send it to a remote base station using LPWAN connectivity. Besides minimizing infrastructure requirements and production downtime, this solution also offers the benefit of power independence because the transmitter can operate on batteries that last for years. This permits a simplified and wide-scale deployment that can gather vast data from legacy assets and equipment while drastically reducing costs. Furthermore, next-gen LPWAN technologies provide the interference immunity and deep indoor penetration needed to overcome the physical obstructions and environmental complexities of industrial campuses to ensure reliable data communications from these devices at all times.

Today’s LPWAN solutions also offer flexibility and interoperability with existing IT infrastructure and business applications for data management, visualization and machine learning, while ensuring effective integration with future devices, systems and applications.

Given their establishment in the industrial world, 4-20mA industrial sensors will remain a fundamental component of industrial operations for years to come. With the advent of plug-and-play LPWAN connectivity, updating brownfield equipment for IoT is no longer an expensive and daunting task. By breaking down data silos and tapping into unprecedented operational insights in real-time, the opportunities to enhance operations and bolster competitive edge are endless.

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IoT and Sustainability: 7 Applications for a Greener Planet

IoT and Sustainability

BehrTech Blog

IoT and Sustainability: 7 Applications for a Greener Planet

Traditionally, advancements in technology and environmental sustainability have seemed mutually exclusive. We often think of technological advancements as having a negative impact on sustainability. Since the first Industrial Revolution in the mid 18th century, technological innovations allowed humans to exert a greater influence over natural resources. This combined with the ever-growing population resulted in a heavier usage of raw materials and an increased amount of production, leading to a significant resource depletion and rise in CO2 emissions.

Until now, the factors that propel digital innovation and sustainability have been disconnected. One is motivated by extensive technological change led by IoT, AI and robotics, all promising to transform industrial and commercial processes. The other is driven by climate and environmental deterioration as well as geopolitical instability, all of which demand a new approach that prioritizes resource conservation and environmental governance — and in particular intensifies efforts to de-carbonize the atmosphere.

However, with today’s advancements in IoT sensor technologies and wireless connectivity, the two concepts of digital innovation and sustainability have become mutually reinforcing. Companies must embrace digital transformation and its business-critical insights in order to pivot to more energy-efficient practices, use resources more responsibly and organize processes in ways that reduce waste.

Here are 7 impactful ways companies can use IoT for sustainability:

IoT and Sustainability

1. Smart Energy Management

While reduced costs and user comfort has been paramount in the design of HVAC and lighting systems since their inception, customers and communities have placed an increasing emphasis on sustainable technology. Energy consumption accounts for more than 40% of a commercial building’s total energy use. It’s no wonder so many facility managers (FMs) are finding ways to optimize this system’s efficiency.

Until recently, HVAC equipment has often been regulated in a uniform, predefined fashion, causing wasteful problems like overheating or under-heating across the property. In this context, real-time, granular IoT sensor data enables on-demand, micro-zoned equipment control to achieve higher energy efficiency. What’s more, leveraging occupancy data can also unveil important trends in HVAC and lighting needs to optimize equipment schedules. For example, if HVAC and lighting systems are set to operate until 8pm, but data reveals tenants don’t stay later than 7pm, facility managers can cut one hour of daily energy use to greatly reduce their carbon footprint.

When it comes to usage monitoring, wireless utility submeters help deliver consumption data at discrete building areas or even on individual assets – especially energy-intensive ones. Having these insights at their fingertips, facility operators can swiftly identify and locate bottlenecks for counteractive measures.

2. Air Pollution Monitoring

Most of the rising global attention to air pollution focuses on the impacts that ozone, particulate matter and other pollutants have on human health. The World Health Organization (WHO) estimates that air pollution inside and outside the home is responsible for about 7 million premature deaths worldwide. The majority of these deaths—4.2 million—are associated with outdoor pollution. It is a leading environmental risk factor affecting urban and rural populations around the world.

Outside of the devastating impact on health, air pollution also has significant ramifications on climate, water, weather, renewable energy, food and vegetation. Recent innovation in low-cost pollution sensors has enabled a new generation of air quality monitoring that provides actionable high-resolution data at a fraction of the cost of traditional monitoring systems. Companies now have real-time snapshots of where air pollution is coming from and traveling to, and who and what is most affected.

For example, methane, the primary component of natural gas, is a potent greenhouse gas accounting for 20% of global emissions. The largest source of industrial emissions is the oil and gas industry, which loses $30 billion worth of methane each year from operations. In this context, an air quality monitoring solution enabled by a low-power wide area network (LPWAN), can provide operators real-time insight into previously undetectable leaks in far flung, remote locations, as well as the ability to remotely control valves to prevent further methane leakage.

3. Smart Waste Management

As cities grow, so does the amount of garbage we produce. By 2050, the United Nations estimate that 68% of world population will live in urban areas and the World Bank that solid waste will increase by 70%. The inadequacy and inefficiencies of existing trash containers and landfills may lead to the accumulation of garbage on city streets and to illegal dumping, with serious consequences for public health. At the same time, more frequent waste collection means more air and noise pollution, traffic, and higher public costs.

Smart waste management has often been discussed in the municipality context, but its benefits and applicability for enterprises are just as far-reaching. It helps to tackle the persistent challenge of emptying schedules that aren’t aligned with actual demand. With waste production rates varying from one day to another at industrial and commercial facilities, pickup trucks often arrive just to offload half-full dumpsters. Needless to say, this introduces increased costs and wasted resources, not to mention the amount of carbon emission resulted from redundant truck trips. In other cases, waste containers may already be overfilled before the collection schedule, causing unhygienic conditions and the potential for more hazardous emissions.

Wireless IoT sensors can combat these issues by delivering various real-time data on trash receptacles at facility managers’ fingertips. Knowing the current fill level of each container, they can better foresee when one needs to be emptied, as well as understand how much and how quickly each type of waste is being disposed on a daily and seasonal basis. On top of that, temperature and humidity data reveal useful insights into undergoing microbial activities inside individual dumpsters. Having all this information at hand, businesses can optimize the pickup schedule of each waste type for higher efficiency, as well as lower transport costs and environmental footprint. At the same time, they can make informed decisions about the container capacity and location to adapt to the actual demand and avoid unwanted overfills.

4. Fleet Management

There’s an increasing focus on the environmental impact of different fuel types, particularly the affect diesel engines have on air quality. When combined with the ongoing drive to reduce CO2 levels across the board, fleet operators are under more pressure than ever before to make sure their fleet related decisions take environmental factors into consideration.

Location, fuel consumption, idle time, driver behaviour and vehicle health all play a role in the total emissions produced by a fleet. IoT sensors powered by low-power wide area networks provide critical insight into these metrics to better optimize routes, improve driving behaviours and ensure timely vehicle maintenance.

For example, real-time location data allows for more accurate and responsive route planning. This reduces the amount of time vehicles spend idling in traffic, producing harmful emissions. Likewise, IoT sensors can be configured to identify and track sudden acceleration or braking, speeding, high-speed turning, frequent stopping, and slow driving – all of which result in wasted fuel.

5. Smart Water Management

According to MIT Researchers, more than 50% of the world’s population will be living in water-stressed regions by 2050. It’s therefore vital that individuals, companies and municipalities find ways to reduce the amount of water wasted annually. On average 85% of properties waste 35% of their water consumption by means of leaks. At the municipal level, pipe leaks can account for 20-30% of total drinking water. In addition, when factoring in the flood mitigation system, one to two tonnes of material waste per square meter is produced from demolition due to floods. This also makes mitigating water loss essential to reducing the waste that goes into landfill as a result of floods. 

Advances in IoT sensors and wireless connectivity have dramatically lowered the cost of gathering, storing and analyzing data from specific equipment, like pumps or valves, or entire processes like water treatment or irrigation. Sensors can monitor fill levels, control the quality water and be used to detect leaks. For example, by installing leak detection sensors in high-risk areas throughout a building or plant, facility managers can be alerted upon the very first sign of a leak allowing them to take remedial action. Taken a step further, hooking this data into a building management system enables automated responses like shutting off the supply valve or HVAC equipment.

6. Smart Farming

Faced with tough challenges of exploding world population, dwindling arable lands and natural resources, alongside growing extreme climate events, the agriculture sector is under undue pressure. According to the UN’s Food and Agriculture Organization (FAO), worldwide food production will need to increase by 50 percent by 2050 to feed an expected population of nearly 10 billion.

Optimizing farming efficiencies opens the door to a sustainable food production system that can cater to global demand while reducing resource usage and environmental footprint. Powered by granular wireless sensors, smart farming systems deliver real-time data of soil conditions and various external factors that play into crop growth. An analytics platform then processes this data for demand-based, targeted execution of various farming practices like seeding, irrigation, fertilization and fumigation. Having enough reliable data at hand, predictive models can even be developed to help identify and prevent conditions unfavourable to crop health. With IoT technologies, farmers can also monitor their cattle’s well-being and get immediate alerts on the first signs of illness, from anywhere.

Besides reducing inefficient and error-prone human intervention, smart agriculture boosts yields while minimizing chemical, water and other resource utilization. This, in turn, translates into higher production rates at a lower environmental footprint.

7. Cold Chain Monitoring

Roughly one-third of the food produced globally is wasted, with much of that loss occurring along the global supply chain. Overall, that translates to 1.6 billion tons of food, worth about $1.2 trillion, down the chute.

Temperature is considered the most important factor affecting the quality of foods. Improper temperature control and settings in the food cold chain can accelerate the deterioration of food quality, which can increase the generation of food losses and food waste.

Traditionally, personnel along the supply chain have manually read and recorded the temperature of goods to ensure optimal conditions. While this pencil scribble method is highly prone to errors, there also arises the challenge of goods moving through multiple parties (loader, carrier, shipper, and receiver) all of which have a different record-keeping system. This process significantly increases the risk of spoiled products in the event that a log is recorded incorrectly, not on time or unchecked altogether.

Smart cold chains provide end-to-end visibility of the supply chain from production and pallets to cargo and retailers. Wireless IoT sensors can track ambient conditions like temperature, humidity, air quality, light intensity and other environmental factors in any location, from anywhere, 24/7. When a threshold is breached, alerts are triggered in real-time to prompt immediate mitigation and avoid any compromise to the product’s integrity.

While technology has plagued environmental sustainability efforts in the past, it has now become an ally to building a greener planet. The advancements in IoT sensors and wireless connectivity are enabling individuals, companies and government to move to energy-efficient practices, use resources more responsibly and organize processes in ways that reduce or reuse waste.

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IoT for Fleet Management: The Rise of LPWAN

IoT for Fleet Management

BehrTech Blog

IoT for Fleet Management: The Rise of LPWAN

From manufacturing, mining, oil and gas to construction and agriculture, fleets of heavy machinery and mobile equipment are among the most critical assets across industries. IoT for fleet management presents enormous opportunities to augment Overall Equipment Effectiveness (OEE). In the data-driven economy, Low Power Wide Area Networks (LPWANs) emerge as a new viable means of IoT connectivity that Original Equipment Manufacturers (OEM) and industrial companies can’t miss out on.

IoT for Fleet Management

The Role of LPWAN for Fleet Management

To stay connected, industrial mobile equipment relies on wireless technologies. Traditional fleet telematics solutions employ cellular networks for tracking and measuring fleet utilization. However, this approach is expensive as it requires every machine or vehicle to have its own cell plan.

Cellular-based telematics can pay off in transportation and logistics applications where connectivity that transcends territorial boundaries, is a must. However, industrial fleet management in enclosed areas such as factories, open-pit mines, construction sites, and farms, calls for a more cost-effective solution. Furthermore, cellular coverage is far from omnipresent, leaving significant gaps in remote and underground locations.

Purpose-built for low-bandwidth, long-distance sensor data transmission, LPWAN is a new versatile solution to connect cross-industry mobile assets. Providing a range of more than 10 km line-of-sight, private LPWA networks can be flexibly deployed to enable reliable coverage in remote, large-scale industrial campuses. Thanks to very low power consumption, LPWAN additionally allows for many years of battery life – a major benefit as mobile assets are often nowhere near a power source.

With legacy equipment in place, operators are now looking for a “plug-and-play” IoT solution to avoid an expensive fleet overhaul. LPWAN is easy to deploy and retrofit in existing equipment and can be operated at a fraction of the cost of cellular alternatives providing operators with the best possible Return-on-Investment from IoT solutions.

IoT for Fleet Management: 3 Impactful Applications

LPWAN-enabled sensor networks collect information about equipment usage, speed, emission, location and more. These data are then forwarded to the cloud for long-term diagnostics and predictive analysis. Actionable insights can be distilled to help companies optimize productivity, compliance and safety, and ultimately improve their bottom line.

1. Condition Monitoring and Predictive Maintenance

Predictive analytics enables fleet operators to stay on top of maintenance by anticipating and correcting failures before they even occur. Built-in sensors transmit key health and operational parameters of tires, hydraulics, engine and other components of mobile equipment. Using automated alerts, operators are informed of any intolerable deviations that hint at impending or abnormal conditions. This allows for advanced planning of oil and part replacements, along with reparation scheduling to avoid costly downtime.

2. Asset Optimization

Under-utilized machinery with excessive idling time results in wasted fuel while incurring additional fixed equipment costs. Data about idle times captured by telematics sensors allow operators to make informed decisions about the optimal size and composition of their fleets, and whether to buy or lease. Unauthorized usage outside operational hours can be additionally detected to avoid any tampering or theft attempts. Overall, asset utilization data contribute to improving OEE and ultimately, net profit margins.

IoT for Fleet Management
Source: https://www.businessinsider.de/caterpillar-is-embracing-the-iot-to-improve-productivity-2017-11?r=US&IR=T

3. Emission Control and Fuel Consumption Management

As climate change continues to become a top global concern, fleet operators are facing increasing regulations and pressure to curb their carbon footprints. In underground mines, emission control is also critical in sustaining a secure work environment for miners.

With connected equipment powered by LPWAN, operators can monitor exhaust emissions to ensure compliance with environmental and safety regulations. Likewise, information about vehicle status and operating patterns, reveals bottlenecks and enables optimization of fuel usage. For example, low tire pressure can increase fuel consumption and reduce gas mileage.

Final Thoughts: Which LPWAN Technology to Go For?

Not all LPWAN technologies can equally cater to industrial fleet management applications. For example, although supporting end nodes moving at high speed is an absolute prerequisite, many existing technologies are missing this feature. Moreover, harsh industrial environments like underground mines pose great challenges in securing reliable connection due to extreme depths and hostile topography.

In the world of industrial fleet management, the right LPWAN technology must balance core criteria in terms of industry-grade robustness and security, deep penetration, mobility, and scalability.

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Smart Supply Chain Management: 4 Game-Changing IoT Applications

Smart Supply Chain

BehrTech Blog

Smart Supply Chain Management: 4 Game-Changing IoT Applications

Supply chain management (SCM) plays a vital role in every industry; directly contributing to a company’s success and overall customer satisfaction. In previous years, international trade disputes and natural disasters have disrupted supply chain management. These disruptions make a substantial impact – the outcome is expensive at best and catastrophic at worst. They affect a company’s ability to deliver product and drive revenue, and they can easily cause long-lasting brand damage.

COVID-19 has caused another unprecedented setback to supply chain management. 94% of the Fortune 1000 have reported experiencing coronavirus supply chain disruptions. This has created an even more complex challenge as supply chains have become a vital lifeline for distributing essential medical supplies, food and other key necessities where they’re needed most. Not to mention, with the massive shift to e-commerce, retailers are faced with an overwhelming production and delivery process to ensure a seamless online shopping experience.

Challenges in Supply Chain Management

The entire supply chain management process is complex. It involves coordinating across various disbursed, and commonly disconnected supply chain actors like producers, brokers, transporters, processors, retailers, wholesalers, and of course consumers. It often relies on outdated and manual processes to control and monitor a product’s flow from the procurement of raw materials and parts from the beginning of production through delivery to the consumer.

Monitoring and controlling the people, processes, parts and products as they transit through the SCM lifecycle is crucial in order to ensure efficiency, a strong reputation, and increased ROI. Despite the availability of several technological solutions, many companies still lack end to end visibility of their entire supply chain. A supply chain market report says that 63% of organizations have no tech systems in place for monitoring supply chain performance and 46% of supply chain professionals still rely on excel spreadsheets for their operations. This leads to inefficiencies such as missed key dates and milestones, contract lifecycle bottlenecks, issues with tracking deliverables, duplicate orders, failure to place orders and missed payments.

The pandemic has tested the resilience and flexibility of supply chain leaders globally and has highlighted the critical need for a system that is more robust, transparent, agile, and sustainable – but above all, digitally enabled. The Internet of Things (IoT) with new sensor and communications technologies is on the rise towards restructuring the entire process. The power of IoT lies in its ability to continuously monitor, assess and optimize real-time data on all people, processes, and things to provide unprecedented visibility into every process and transaction within the supply chain.

The Role of IoT in Smart Supply Chain Management

1. On-Road Asset Tracking

Supply chains have been transformed beyond recognition over the last year. Curbside pickup, BOPIS (Buy Online, Pickup in Store), shipments to neighbors, smart lockers, as well as direct to consumer (D2C) deliveries by manufacturers have become commonplace. Even perishable goods are in high demand with the advancement of more robust cold chains solutions for categories ranging from pharmaceuticals to meal delivery services. This is creating demand for on-road asset management solutions.

Connected sensors can track items from “floor to store.” There are a variety of IoT sensors that can provide a coherent stream of real-time data on the exact location of an item, how long it took to move between different phases of the SCM lifecycle and even how fast a specific delivery truck is moving. This helps identify bottle necks, allow for contingency planning and determine alternative routes to speed up delivery. It also helps suppliers, manufacturers and distribution centers better prepare to receive goods, which reduces handling times, ensures the efficient processing of material and increases the precision of delivery forecasts for vendors and consumers.

2. Cold Chain Monitoring

Some goods like food and pharmaceuticals need to be stored in ideal conditions. With a smart cold chain, you can monitor, locate, and address any potential errors quickly. For example, environmental sensors can track ambient conditions like temperature, humidity, air quality, light intensity and other environmental factors inside a storage facility, cargo container or delivery vehicle. When a threshold is breached, alerts are triggered in real-time to prompt immediate mitigation and avoid any compromise to the product’s integrity.

3. Warehouse Management

Warehouse errors can be costly. Nevertheless, the absence of an effective inventory management approach is not uncommon. Many businesses still manually track their inventory using spreadsheets and paper-based methods. This approach puts data at risk as Marketwatch estimated that 88% of spreadsheets contain errors. This makes indoor wireless IoT solutions highly instrumental in warehouse management.

IoT can help reduce manual labor, errors, and help increase processing speeds and overall warehouse efficiency. Connected sensors can be used to monitor the movement and use of material, products and other assets inside facilities to maximize their effective use, prevent loss or theft, reduce search time and avoid out-of-stock scenarios.

Connected sensors placed on shelves and storage bins can also communicate stock levels in real time to identify usage patterns. This continual feedback helps streamline coordination between warehouse operations and various logistics providers and can help use space more efficiently.

4. Fleet Management

As the supply chain continues to grow, it’s even more imperative to ensure that all carriers—be it shipping containers, suppliers’ delivery trucks, or a van out for delivery—are connected.  IoT sensor networks can collect information about vehicle usage, speed, emission, location and more. Built-in sensors transmit key health and operational parameters of tires, hydraulics, engine and other components of mobile equipment to enable predictive maintenance.

Telematics sensors can pinpoint under-utilized machinery or excessive idling time to avoid wasted fuel and allow operators to make informed decisions about the optimal size and composition of their fleets. Unauthorized usage outside operational hours can be additionally detected to avoid any tampering or theft attempts. Operators can monitor exhaust emissions to ensure compliance with environmental and safety regulations. 

Sensors equipped with GPS can also give supply chain managers a more accurate estimation of delivery to help reduce wait times at destinations and improve the supply chain workflow.

Finding the Right IoT Connectivity

From location, temperature, humidity, light, movement, handling, speed of movement and other environmental factors, there are numerous IoT sensors that promise to deliver critical business insights for improving supply chain management. The challenge is finding reliable IoT connectivity to ensure this data is delivered accurately, in full and on-time.

Emerging IoT connectivity solutions like Low Power Wide Area Networks (LPWAN) are redefining the possibilities for SCM. Geared for low-bandwidth, low computing end nodes, newer LPWAN solutions offer highly power-efficient and affordable IoT connectivity for any large, structurally complex or remote facility along the supply chain from industrial campuses and warehouses to distribution centres and retail. No current wireless classes can beat LPWAN when it comes to battery life, device and connectivity costs, and ease of implementation. As the name implies, LPWAN nodes are designed to operate on independent batteries for years, rather than days as with other wireless solutions. They can also transmit over many kilometers while providing deep penetration capability to connect devices at hard-to-reach indoor and underground locations.

2020 has been a challenging year for supply chain management, but it has also presented enormous opportunities for change. Innovative IoT sensors coupled with robust and scalable LPWAN connectivity are enabling a new interconnected and informed supply chain ecosystem that improves operational efficiency, brings more transparency to the communication process, and increases precision planning.

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3 Reasons Industrial IoT Projects Fail and How to Overcome Them

3 Reasons IoT Projects Fail

BehrTech Blog

3 Reasons Industrial IoT Projects Fail & How to Overcome Them

With the global market size predicted to reach USD 949.42 billion by 2025, Industrial IoT (IIoT) is expected to bring game-changing opportunities to improve operational visibility, efficiency and productivity, all while lowering costs. Amid this ambitious potential, an IIoT implementation is often easier said than done. A Cisco study revealed that only 26 percent of business decision-makers could name one of their IIoT initiatives a success.

Each project is unique, but the challenges faced are similar. In most cases, replacing existing facilities and equipment with entirely new, greenfield plants with native IoT technologies is simply not feasible. As such, brownfield IoT deployments are the way to go, but there exist a multitude of challenges. Designed in the previous century, legacy assets and systems aren’t meant to be connected to the outside world and thus lack effective communication functions. On top of that, companies haven’t prepared themselves to deal with security and data privacy issues in the IoT era.

In this article, we take a look at the top reasons industrial IoT projects fail and how to overcome them.

3 Reasons IoT Projects Fail

1. Connectivity

While data communications have long existed in industrial automation systems, they are built for closed-looped control tasks only. As such, machine and operational data are often trapped within multiple process silos on the factory floor. Connecting these systems via Ethernet is expensive, cumbersome and conducive to production shutdowns. In many industrial settings like open-pit mines and oil fields, asymmetric topography and vast geographical areas make trenching wires almost impossible.

Solution

The IIoT value chain essentially starts with data collection and choosing the right connectivity solution might ultimately impact the success of your IIoT initiative. There’s a plethora of wireless technologies in the market, but not all of them can keep up with the demanding industrial environments. Long-range, deep penetration and high interference immunity of the radio link are key to reliable data connection over large industrial campuses. Also, you’ll want to have a unified communications solution to extract data from existing industrial networks and to support a new layer of granular, battery-operated sensor networks for complete operational visibility. In this context, low power consumption and high network scalability are other critical wireless criteria not to overlook.

2. Integration

According to a report by Bain & Company, difficulties in integrating IIoT solutions with existing operational technology and IT systems continue to be a major adoption barrier. These difficulties center around how data is ported across different formats. Many companies struggle to retrofit IIoT technologies into legacy equipment like Programmable Logic Controllers (PLCs) without involving complex, error-prone modifications. On top of that, how to integrate collected data into existing IT and enterprise management platforms is another reason industrial IoT projects fail. 

Solution

Emerging plug-and-play IIoT solutions are easing integration tasks with the use of a converter or an integration gateway. On one side, the converter interfaces with brownfield PLCs using automation-specific protocols to gather critical production data, reformat and then transmit it using robust, long-range connectivity on the other side. By leveraging such a solution, companies can bypass invasive hardware reprogramming and costly production downtime in a brownfield deployment. In addition, going for an open, API-driven IIoT architecture could greatly simplify integration and data transfer to legacy enterprise applications, software and reporting and analytics tools.

3. Security and Data Privacy

There are no IIoT discussions without security and data privacy concerns. Massive financial and operational damages caused by a breach is a primary reason companies shy away from IIoT and why IoT projects fail. The fact that many legacy industrial control systems have limited or outdated security features, further intensifies these challenges.

Solution

All of that said, there are a few steps companies can take to tackle security and data privacy issues. First, selecting an IIoT architecture with built-in end-to-end security for both non-IP and IP-based data transfer is critical. Advanced Encryption Standard (AES) is a proven security mechanism for non-IP, low-power connectivity, while Transport Layer Security is an industry-standard cryptographic protocol for Internet-based connections. Besides data encryption, employing one-way connectivity to collect data from critical automation systems helps circumvent attempts to remotely control machines through reverse communications. If retaining data on-premise to avoid privacy concerns is a top priority, a privately managed and controlled network is preferred over public connectivity services.  

As with previous industrial revolutions, IIoT does not come without challenges. However, addressing and overcoming these challenges with the right technologies and solutions opens the door to immense opportunities to gain more operational visibility, improve efficiencies and lower costs.

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5 Reasons Industrial Remote Monitoring Will Soar in 2021

Remote Monitoring

5 Reasons Industrial Remote Monitoring Will Soar in 2021

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In 2020, remote operations and management emerged as a business-critical activity across industry 4.0. While the digitization of operations is already recognized as a key driver to competitive differentiation, COVID-19 concerns have increased the pressure for new levels of efficiency, productivity and safety from a distance. Companies must innovate in order to stay resilient during these challenging times which makes process improvements, improved supply chain management, and investments in information technology and automation critical. Thanks to the advancements in IoT sensor technologies and wireless connectivity, industrial organizations can make a seamless transition to remote monitoring that ensures business continuity and peak performance 24/7. With access to rich real-time and historical data of processes, assets and plant personnel, organizations can better manage production, maintenance and improve safety across multiple sites.

Here are the 5 reasons remote monitoring will soar in 2021

1. Ensure Employee Health and Safety

The pandemic has urged most organizations to transition to a remote workforce, where possible. While many jobs across industry 4.0 still require onsite presence, environmental monitoring, asset management and predictive maintenance solutions allow more of the workforce to work remotely, while maintaining the integrity of the business. Sensor data collected from assets, machinery and facilities can be used to manage equipment performance and utilization, quality assurance, inventory levels and plant operations, 24/7 from anywhere. When a failure is imminent, the monitoring system can communicate directly with service teams, ensuring an expedient repair or service process and eliminating the need for employee intervention entirely.

On the other hand, IoT applications such as remote condition monitoring, provide real-time insights into the performance parameters of machinery and can prevent impending failures or hazards that could potentially threaten the safety of onsite employees. Likewise, applications such as occupancy and presence detection can ensure safe distancing practices are met onsite and janitorial services are deployed when necessary.

2. Reduce Operating Costs

One of the biggest factors driving remote monitoring is reduced operational expenses, especially with the increasing pressure to stay afloat during the pandemic. It is estimated that industrial manufacturers incur a $50 billion cost every year due to unplanned downtime, and maintenance expenses make up 15% to 40% of total production costs. Remote condition-monitoring predicts and prevents serious equipment failures ahead of time to maximize equipment uptime while reducing maintenance costs. Moreover, remote monitoring and automatic reordering of raw materials helps prevent costly production halts caused by low supply levels. It also helps avoid excess inventory which can cause freight-in, storage and insurance costs. Labor costs are also reduced as remote operations facilitates more effective multi-site monitoring which requires fewer personnel overall.  

3. Maximize Uptime

Any time equipment is not operating during business hours, production suffers, and significant costs are incurred. Remote monitoring plays a central role in predictive maintenance practices to avoid unplanned downtime and equipment failures. IoT sensors are used to track and analyze the status, performance and stresses of critical assets like motors, pumps, and conveyers. For example, monitoring equipment vibration reveals important insights that can indicate looming failures. An unwanted increase in vibration intensity produces detrimental forces to the components which jeopardize equipment lifetime and quality. Without timely intervention, asset failures and process shutdowns are inevitable. Remote monitoring alerts personnel of potential issues in real-time so they can immediately troubleshoot issues, modify an operating parameter or provide on-site workers with instructions as to how best fix a problem or improve performance. Even when issues cannot be prevented, remote monitoring can help rapidly resolve issues that do occur, accelerating mean time to repair and first-time fix rates to ensure maximum uptime.

4. Quality Control and Assurance

Beyond reactive, end-of-run quality inspection, remote monitoring enables a proactive quality control approach to diagnose and prevent defects much earlier in the process for peak production rates and repeatability alongside reduced costs and waste. Equipment-related issues and ambient conditions can significantly impact the quality of raw materials and end products, both during production and in storage. For instance, inadequate air pressure can cause dust infiltration which can significantly impact product quality and even damage machinery and production equipment. Similarly, temperature fluctuations in processing and storage facilities can impact quality assurance and safety, especially in the food and beverage industry. Remote monitoring provides a wide range of critical machine, process and environmental data in real-time so managers can quickly identify problems and root causes for quick and remedial action such as adjustments to equipment or the HVAC system.

5. Replicate Success

For larger manufacturers with multiple plant locations, remote monitoring offers a consolidated model of performance trends across all sites. From a central location, data can be compared to identify and replicate the successes of the highest performing plants. Detailed historical information can also be compared across facilities and analyzed to identify potential problems early and enable managers to implement changes to improve efficiency, cost-effectiveness and safety.

With the future of industrial operations uncertain, organizations must remain flexible and adaptable. Investing in IoT sensor technologies and scalable wireless IoT connectivity is essential to respond to changing customer needs, better manage production changes and drive operational excellence in any condition.

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18 Essential Stats about IoT for Asset Management

IoT for asset management

BehrTech Blog

18 Essential Stats about IoT for Asset Management

From manufacturing, mining and oil and gas to construction and healthcare, businesses across all verticals work with vast amounts of machines, equipment and mobile tools every day. Effective asset management has a major impact on operational productivity and companies’ bottom line, and yet this has traditionally been plagued by poor visibility into existing asset use and conditions. The application of IoT for asset management opens compelling opportunities to optimize equipment efficiency and asset lifecycle management.

Asset Management Hurdles

The old-school way of managing assets incorporates visual inspections, handwritten lists and excel sheets to track the current status, location and performance of heterogeneous equipment. Without a doubt, this approach is labor-intensive and inefficient, while failing to provide sufficient asset information. As such, employees often waste hours searching for dispersed tools and parts or make redundant supply orders, which results in substantial costs and productivity loss. Due to the lack of visibility, valuable assets are also highly susceptible to thefts and vandalism attempts.

What’s more, poor insights into actual equipment health mean that devices are often serviced too frequently or too late, and spare parts can easily run short. When it comes to mission-critical machinery, a single failure could disrupt the production line partially or even entirely, causing expensive downtime and delaying product delivery. On the other hand, redundant, scheduled-based preventive maintenance that overlooks real-time equipment conditions, is inefficient while introducing extra expenses and waste. The challenge of asset management further amplifies at hard-to-access, geographically dispersed industrial sites with numerous unattended assets.

You might also be interested in: 20 Mind-Boggling Stats on Industrial Downtime

Benefits of IoT for Asset Management

With the Internet of Things (IoT) comes a new generation of low-power, wireless sensors that can turn normal physical objects into digital devices with communications ability. Attached to individual assets, these sensors capture and report detailed information about current asset conditions as well as where and how they are being used. Leveraging robust, long-range IoT connectivity, insights into even the most remote, isolated assets can be gathered at the control center and easily accessible by plant operators and technicians. By having a holistic, real-time picture of cross-site assets, they can quickly pinpoint underutilized equipment, diagnose impending issues and bottlenecks, and easily mobilize tools and parts. Ultimately, the application of IoT for asset management enables organizations to optimize maintenance activities and asset useful life, while eliminating error-prone manual records and excessive orders.

The infographic below captures 18 essential stats about asset management challenges across industries and how IoT can deliver tangible values in this context.

Asset Management

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