Nokia Interviews Lead To Insights From the Chemical and Plastics Industry About IoT and Industry 4.0
Earlier this year, Nokia interviewed leaders in the chemicals and plastics industry – from C-suite executives to supply chain managers – across Europe and the United States to hear how digital transformation – and tools like AI and machine learning (AI/ML) – are impacting their organizations. For many of them, using Industry 4.0 technologies – such as IoT, analytics, and digital twins – was a considerable focus in enabling them to capture data and utilize the power of AI/ML in their operations.
The biggest takeaway is that the entire industry is well on its way to going digital. Many of the largest companies are already well down the track, while smaller organizations must catch up and wish they had started sooner. But, for the most part, they all agree that digitalization can make their businesses more efficient while improving security, safety, and sustainability and eliminating human error.
The interviews also uncovered some interesting trends and challenges within their industry that can be met head-on and remedied with private wireless.
1. Optimization Requires Removing Data Silos
Today, many chemical and plastics factories use digital measurement and control to manage their production processes, some of which have been used for several decades. However, these systems are typically purpose-built with proprietary hardware and software, featuring data formats incompatible with neighboring processes and systems. As a result, most companies have separate data lakes with little or no data sharing between them. Eliminating the barriers between legacy systems is costly, and additional custom integration complicates upgrades.
This situation can present several challenges. For a factory manager tasked with optimizing overall operations, it can mean an increase in daily paperwork and administrative tasks, a lack of real-time dashboards for the operation, and complex and time-consuming analysis. This can slow decision-making, increase the likelihood of human errors, and force management to be reactive rather than proactive.
2. Make Sense Of The Data Firehose
As IoT technologies allow companies to collect data that wasn’t available to them before, more small-to-medium enterprises (SMEs) are getting on board with these new technologies. Many of them are deploying condition monitoring sensors that can measure temperature, flow, pressure, and levels for processes. This new data is then analyzed and applied, resulting in more efficient energy consumption, better quality control, less waste, and – most importantly – greater safety.
Many large organizations have already implemented IoT in their operations and are using that data today. Now that they have the data, their next step is to use it in real time. One of the methods they’re deploying is to use digital twins – automated models that run alongside the actual processes. By doing this, they’re able to see exactly what their process is currently doing while also being able to anticipate the intended outcome and potential alternate outcomes. This allows them to control quality, save energy, adjust their resources, and avoid potentially dangerous outcomes.
The ultimate goal – which few organizations have achieved – is to fully optimize their processes using AI/ML. The biggest challenge in achieving full optimization is the need for high-quality real-time data throughout their operations. Interestingly, this isn’t an issue exclusive to the chemical industry – many industrial sectors now recognize that one of the most important advantages in the AI/ML era is having good quality, proprietary data.
3. The Connected Worker Replaces The Control Room
One interviewee shared an anecdote when in one project, he asked the people building the plant where the control room would be. They replied, “We don’t have one. Our control room is wherever the operator is. Each operator would have a device to see exactly what was happening with each operation in real-time”.
As with many industries, an aging population poses operational challenges. As the “baby boomer” generation retires, organizations are facing challenges with recruiting their replacements, and being able to use automation to “do more with less” is becoming a high priority.
Once new hires are made, there’s also an issue of training. Senior engineers who may have spent a decade or more in their role have vast knowledge and experience that needs to be transmitted to their replacements. Organizations find that virtual and augmented reality are exciting areas to explore for training.
Additionally, the new generation of employees has grown up in, and is accustomed to, a digital world. Therefore, providing their employees with digital tools is becoming an increasingly competitive advantage as their employees are able to perform faster and more effectively with real-time data and information available.
4. Cybersecurity Needs To Be In Focus
Cybersecurity has long been a focus for organizations, but as more digital tools are integrated, the attack surface and points of intrusion are becoming larger. In addition, many governments and regulators are adding another layer to the issue of cybersecurity by adding new rules around security and compliance, thus increasing the level of concern for many organizations.
Find A Partner That Can Simplify Digitalization
Ultimately, the most significant takeaway from the interviews was that organizations are looking for partners to remove the complexity surrounding digital tools to help them reach the next level. Many are looking for a holistic solution that integrates digital technologies across their entire operation. This process begins with wireless connectivity integrating sensors and low-latency, high-bandwidth applications. Also, it includes edge solutions that can provide local data processing, ready access to application libraries, and devices to connect with their workforce – all protected by best-in-class cybersecurity solutions.
Infinity Technology Solutions is the partner you need to deliver these solutions and others.
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