Edge Computing: Making Manufacturing Smarter, Faster and Safer Than Ever

While manufacturers have been leveraging industrial automation for centuries, now more than ever, the introduction of edge computing and AI is transforming the way factory managers think about efficiency and how to make quick, profitable decisions. With Internet-of-Things (IoT-) connected machinery, advanced sensors and evolving analytics tools, manufacturers can automate equipment and streamline processes in ways that have never been possible before. As a result, many manufacturers have cut costs, improved production quality and boosted profit.

The key to this unprecedented efficiency lies in the swaths of data coming from these connected devices. However, that information can be difficult to leverage without a well-planned strategy for storage and processing. Traditionally, manufacturers have turned to centralized data centers — or “the cloud” — to support their data-driven operations. But as technology continues to evolve and data lakes expand, cloud computing may not be fit to support manufacturing’s most mission-critical applications.

The disconnect between factories and the cloud

Cloud architecture has long been a go-to for manufacturers due to its ease of access, scalability and cost efficiency. Those qualities are valuable to businesses, but, as the volume of data being generated on the factory floor grows and industrial applications become more complex their shortcomings are beginning to reveal themselves.

To maximize efficiency in today’s manufacturing landscape, factory managers need to be able to make real-time decisions. When machine data indicates potential downtime on the horizon or automated processes need spur-of-the-moment adjustments, every millisecond counts. But, if all that data needs to be transferred to and processed at a centralized hub away from the factory, it introduces latency, increasing the time between detection and correction.

Latency slows down automated processes and can spell trouble for manufacturers who rely on constant data flows to understand their machine health, product quality and more. Delays in receiving this information can result in costly downtime or product defects, and even more, hinders modern-day manufacturing assets from performing at their fullest potential. Emerging smart technology, such as AI applications, robotics and autonomous guided vehicles, rely on instant data transferring and processing, becoming less functional when latency is introduced to the factory floor.

As smart technology continues to grow in popularity, so does data volume and the cost of system operations. Not only are constant data transfers to the cloud expensive and strenuous on the network, but an overreliance on cloud computing takes control out of the manufacturer’s hands. Once data is transferred, businesses can no longer protect their information from cyberattacks. Faced with threats of financial loss and reputational damage, a new way of computing this data can help manufacturers work faster, smarter and safer.

Edge computing is designed to put applications and data as close as possible to the technology that needs them. In manufacturing, this could mean processing data directly on the factory floor using devices like sensors and cameras instead of the cloud, enabling real-time decision-making and faster response times, a crucial step in adopting some of the most efficient modern-day technology. When manufacturers process data at the edge, transfers, analysis and storage all occur within that facility, reducing latency and safeguarding business’s most critical data from the prying hands of hackers.

Deploying edge devices: Work faster, safer and more efficiently 

Edge computing can bring a new era of industrial automation in reach. Now is the time to consider how your facilities can benefit from these devices and how they fit within your already complex web of connectivity. By analyzing current structures and understanding where factory processes could benefit from latency-free computing, manufacturers can elevate their production capabilities and deploy edge-enabled devices without friction.

Decide which technology to prioritize for real-time connection

While cloud computing can still be utilized for non-time-sensitive data processing, numerous manufacturing processes like quality control, machine monitoring and process optimization require immediate analysis and authority. Additionally, modern-day manufacturing assets like robotics and other autonomous operations, which utilize AI and real-time data to determine workflow within the factory, thrive by computing at the edge.

Understand how edge devices will be integrated with existing systems

In a complete IoT infrastructure, edge and cloud computing work in tandem to process “high-volume, low-value” data instantly for the devices that need it while offloading “low-volume, high-value” data to the cloud, maximizing efficiency while also remaining cost-effective. Manufacturers need to consider how edge will integrate into their existing cloud architecture and keep current factory infrastructure top of mind. Investing in a working relationship between all devices on the factory floor is at the core of maximizing productivity, such as using an edge-native tech stack to classify data and make decisions on where that information should be processed.

Create a connected ecosystem of edge devices for maximum productivity

Interoperability is crucial for building flexible, scalable and collaborative edge ecosystems that will facilitate seamless data transfers and reduce complexity on the factory floor. When edge devices are in sync, manufacturers can tap into an unprecedented well of productivity and efficiency.

Manufacturing’s new horizon

Edge computing and smart applications enable real-time data processing and analysis closer to the source, which can optimize manufacturing efficiency and help workers achieve the previously impossible with cloud’s latency-riddled computing. With a few considerations, manufacturers can deploy edge devices to their automated fleets and process data directly on the equipment that needs it most. Even more, advanced messaging systems such as NATS.io (NATS) exist to seamlessly handle edge-to-cloud and within-the-edge communications, a critical aspect of maintaining an efficient manufacturing environment.

With instant insight into machinery data through edge computing, manufacturers can respond immediately to changing conditions and reap the benefits of cutting-edge, automated technology.