Pros and Cons of Sensor Technology
The Importance of Sensor Technology in Manufacturing
There are many published articles on how sensor technology can play a critical role in manufacturing. Sensor technology can definitely provide real-time data and feedback on production processes which allows manufacturers to optimise production efficiency, improve quality control, and reduce costs. Sensors can also be used to monitor equipment performance, detect defects, and track inventory levels. Overall, it is said that sensor technology will help manufacturers improve the speed, quality and efficiency of their production processes.
Is it all too good to be true though?
Like with everything, there are always pros and cons. Let’s look at the reported pros of sensor technology in a little more detail first, which can include:
1. Improved efficiency and productivity: Sensors can provide real-time data and feedback on production processes, allowing manufacturers to optimise efficiency and improve quality control.
2. Enhanced safety: Sensors can be used to monitor equipment performance and detect potential hazards, helping to prevent accidents and protect workers.
3. Cost savings: By providing accurate data on production processes, sensors can help manufacturers reduce waste, lower energy consumption and optimise inventory levels.
4. Advanced manufacturing processes: Sensor data can be integrated with other systems, such as automation and robotics, to enable advanced manufacturing processes such as Industry 4.0.
5. Remote monitoring and control: Many sensor technologies are designed to be remotely accessed and controlled, allowing manufacturers to monitor operations from anywhere in the world.
And here come the reported cons!
1. The cost: The cost of sensor technology can be a significant investment, especially for small and medium-sized enterprises.
2. Data management: sensor technology can generate large amounts of data, and managing, processing and analysing it can be a challenge for many manufacturers.
3. Complexity: Sensor technology can be complex and difficult to implement, especially for manufacturers with limited technical expertise.
4. Integration challenges: Integrating sensor technology with existing systems can be complex and time-consuming, requiring specialized expertise and resources.
5. Maintenance and repair: Sensors are mechanical or electronic devices and may require regular maintenance and repair to ensure accurate and reliable performance.
It is fair to say that, if implemented correctly, sensor technology has many benefits for manufacturing operations which can outweigh the cons. But potential drawbacks must also be considered carefully when deciding whether to invest in sensor technology.
Tom Reames of Maintmaster with our consultant Kevin Sullivan
Speaking to our Partner – Maintmaster
We spoke with Tom Reames, the Sales Director for Maintmaster*, one of our sensor and CMMS providers to find out what really are the most common issues faced for manufacturing companies when trying to work with, or implement an Internet of Things (IoT) strategy in their plant or facility. This is what Tom told us:
I believe the adoption of the IoT amongst maintenance and engineering departments, particularly within manufacturing and other key plant and asset heavy industries in the UK, has been low due to real barriers, as well as perceived barriers. Here are some of the concerns we hear:
“Am I going to be investing in IoT sensors and gateways where the technology is going to be outdated or obsolete within a short period of time and we’ve invested Capex in this hardware?”
“Am I going to be putting my trust in an integration by two disparate technology companies whose interests may change in the future and the integration the sensors linking to the EAM/CMMS relies on may no longer be valid?”
“Am I going to be signing multiple contracts and agreements with various suppliers where the lines of responsibilities may become blurred?”
“Why is the solution provider for the IoT side not able to clearly indicate a cost or even Rough Order of Magnitude (ROM) cost for me?
“Why is the pricing model so complex?”
Tom also explained that the Maintmaster* solution can eliminate some, if not all of these concerns:
Our sensor solution hardware is leased as part of a SaaS agreement and so, if new improved hardware becomes available it will be covered as part of the SaaS contract.
Our single supplier, single contract relationship gives security and a working solution. It is an EAM/CMMS with pre-integrated IoT sensor solution – with automation of workorders.
The pricing model is simply based on the number of sensors and scales accordingly. The Return on Investment (RoI) is clear. We are able to demonstrate a reduction in breakdown Corrective Maintenance and increase in Planned Preventive Maintenance (CbM and PdM fall under this). Generally, Corrective Maintenance costs are approximately 3 x as much as Planned Maintenance, so the potential savings are an easy calculation.
Let us not forget the initial cost though!
The cost of sensor technology can vary widely depending on the type of sensor, its accuracy, and the complexity of the application. Some sensors, such as basic temperature sensors, can be relatively inexpensive, while others, such as high-precision sensors for aerospace or medical applications, can be very expensive. Additionally, the cost of implementing sensor technology can also include expenses for installation, calibration, and data management.
However, the cost of sensor technology has been decreasing in recent years, making it more accessible to small and medium-sized enterprises. The packaged solutions that Maintmaster* provide, as an example, are ideal for companies who want to test the water and have a scalable, proven model to expand in the future.
Let’s not forget the general benefits of sensor technology, such as improved efficiency, quality, and cost savings that can often offset the initial costs over time, making IoT technology a worthwhile investment for many manufacturing operations because of the benefits it brings.
*MCP Consulting Group Ltd. are the UK Partner for Maintmaster
Where to start…
If you are not sure where to start your IoT journey or have already begun but hit some hurdles along the way, speak to us. Following our Technology Audit, we can provide you with the help, advice and support you need, to ensure your technology implementation gives you the benefits you should be expecting, in the short to medium and long term.
eBook - Guide to the IIoT
The purpose of our eBook - Guide to the IIoT, is to describe some of the concepts of the Industrial Internet of Things and how you can get started on your journey. We provide suggestions on what companies can do to get equipment connected, start gathering data and put the data to use.
In our eBook - Guide to the IIoT, we cover:
An overview of Industry 4.0
How the IIoT works
The downsides of IIoT
Overview of maintenance strategies
How to start your IIoT journey
The benefits of the IIoT
Frequently asked questions
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