In recent years, IoT sensors have become the go-to standard when it comes to increasing production up-time and efficiency in the manufacturing industry. Reducing downtime in any facility is key to such efficiency. Some causes of downtime include lack of planning, poor operation (by human error or machine error), time spent on maintenance, and lack of predictive maintenance. There are a number of sensors available for the manufacturing industry that can provide the necessary data to avoid downtime. NCD manufactures over 100 sensors to help increase efficiency and reduce down time for many industries: Automotive, chemical, steel manufacturing, packaging, waste water management, agriculture, warehouses, oil, and gas, etc. IoT Sensors can be utilized in almost any industry to fill a need to monitor assets and resources.

What is IoT Sensor

There is no set of fixed rules that a device has to follow in order to qualify to become an IoT sensor. The goal of installing or using an IoT sensor is to convert a physical parameter into a digital parameter. From this point, the user will send data to a cloud service, which will translate raw data into usable information. In general, there are a few things users look for when it comes to IoT sensors;

1. Wireless Communication
2. Battery and External Power
3. Communication with a Gateway (News - Alert)
4. Cloud Compatibility
5. Sensor ecosystem

IoT Sensor By Industry

IoT sensors can be used by a plethora of industries interested in data collection of any kind. NCD produces sensors for a variety of industries.  There are many common parameters and data points that are universally sought by countless industries. The lists below show the versatility of NCD’s IoT Sensors and how many applications they can serve. Some of NCD’s multifaceted IoT sensors include: Temperature/Humidity Sensors, Current Sensors, Temperature Sensors, and Analog Sensors. Below are lists of various industries that can utilize IoT Sensors on a daily basis.

Manufacturing Sector

• Temperature Sensor
• Current Sensor
• 4-20mA Sensors
• Vibration and Temperature Sensors
• Accelerometers
• Digital Inputs
• Analog Inputs

Healthcare Sector

• Temperature Sensors
• Air Quality Sensors
• Co2 Sensors
• Open/Close Door Sensors

Power and Utilities Sector

• Temperature Sensors
• Current Sensors
• Voltage Sensors
• Vibration Sensors
• Tilt & Inclination Sensors

Oil & Gas Sector

• Temperature Sensors
• Vibration Sensors
• Leak Detection Sensors
• High-Temperature Sensors
• Pressure Sensors
• Tank Level Sensors

HVAC Sector

• Temperature/Humidity Sensors
• Air Flow Sensors
• Air Quality Sensors
• RTD Sensors
• Pressure Sensors

Agriculture Sector

• Soil Temperature Moisture EC Sensors
• pH ORP Sensors
• DO and EC Sensors
• CO2 Sensors
• PAR Sensors
• Temperature/Humidity Sensors

How To Build an IoT System

Building an IoT system may appear to be very straightforward, but statistics show, that over 75% of IoT projects fail. A few main reasons behind such failure are:

1. Hardware 
2. Cloud Software
3. Physical Integration

For better or worse, it’s very difficult for a single company to provide its own top-notch, IoT solution. All companies that work with IoT have their strengths and weaknesses, and in order to build an ideal IoT system, it’s ideal to work with three different entities to generate the best results possible when gathering data.

Hardware Manufacturer — Once the requirements are partially or fully identified, the user will need to seek out a hardware manufacturer that supplies the tools which may be used for the application. While searching for the correct hardware, users generally  want to consider the following:

• Security
• Wireless Range
• Scalability
• Hardware Ecosystem
• Any hidden fees associated with hardware
• Power Option
• Ease of use
• Ease of Installation
• Cost

*NCD manufactures IoT hardware that checks all of the above criteria.

 Cloud Provider — The user has a few options to consider when choosing a cloud provider:

• Any existing cloud solution — Many companies may already have or use a cloud service like AWS, Azure, etc. If this is the case then the user can continue to utilize the cloud service already in place for an IoT project as well.
• Build Your Own — For some, building a cloud service from the ground up might be a long road. However, given the correct resources, it may be an ideal situation if the user desires an IoT solution across multiple locations.
• Use Third Party Cloud Services — NCD IoT hardware is compatible with nearly any cloud platform on the market. NCD recommends that users should utilize a third party cloud service for pilot projects – especially if a cloud service is not already in place.
• Local Data Processing — In some cases, users will also choose to log and process data locally. In such cases, Node Red will be an ideal choice.

System Integrator — It’s always recommended to incorporate a system integrator into an IoT project. In NCD’s experience, if the user has a system integrator involved in their project(s), the chances of success increase up 3 to 4 times. There are multiple levels of system integrators to choose from, based on the user's comfort level with the project.  There are even system integrators who will take the project from pilot, all the way to full integration!

Bottom line – factory operators and manufacturers need and rely on precise data regarding uptime and production downtime in their facilities. If there are resources being lost due to unnecessary downtimes, there’s no longer an excuse to not track such data and plan and execute a way to reduce such downtimes, thus saving much time, assets, materials, funds, etc. NCD has a sensor for all of your production needs!

About The Author –

Anil Bhaskar

Anil Bhaskar works as CEO and Director of Engineering at ncd.io. NCD has been designing and manufacturing Industral Devices since 1995. Anil Bhaskar has designed over 500 products throughout his engineering career. NCD sensor are being used around the globe and solving manufacturing problems on daily basis.