The Role of AI in Industrial IoT: Improving Efficiency and Quality Control

The Role of AI in Industrial IoT: Improving Efficiency and Quality Control
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7 min
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Nowadays, it seems that everywhere you turn, there’s a new talk about how AI and IoT can make our personal and professional lives easier. Of course, it’s for a good reason because we were bound by our physical, human limits in many areas and we cannot resist the prospect of a productive, hassle-free life with these solutions. 

Now, with the arrival of Industrial IoT (IIoT) and the concept of Industry 4.0, we can finally imagine a future where companies can boost efficiency and reduce errors while we don’t have to worry so much about sustainability and energy management. 

In general, you can explore the impact of AI in three key areas: Predictive maintenance, quality control, and smart manufacturing.

AI for Predictive Maintenance

Machine learning and artificial intelligence can have a significant influence on the field of predictive maintenance. In reality, a significant portion of AI implementations have to do with maintaining equipment and manufacturing tools.

The speed and accuracy range of AIoT predictive maintenance is its two most important advantages. AI can detect mechanical issues with sufficient speed and accuracy to perform repairs before breakdowns take place.

Intrusion detection models examine structures and parts to find indicators of stress or abnormality, whereas regression models and categorization models utilize historical data to foresee breakdowns. These techniques and models are all examples of AI & IIoT in predictive maintenance.

AI-Powered Quality Control

Any healthy industry depends on your ability to conduct thorough inspections at every level of operation. The inevitable human error is the main contributing cause to the high rates of waste and failure associated with manual quality control. With the help of IoT, companies can identify defects much more quickly, which ultimately costs less money for them.

Thanks to the perfect blend of AI and IoT, many applications, such as visual inspection technologies, in the modern age of Industry 4.0, help businesses identify errors and flaws in their goods or manufacturing processes in real-time.

Using AI-enabled analytics, companies can train their platforms to instantly identify faulty items and shut down production, with little or no need for human supervision.

The adoption of IoT has also decreased the degree of trial and error in areas that are too intense for people, such as blast furnaces since the platform can detect when an item is done and when it is not, minimizing the issues with inconsistent quality throughout manufacturing output.

AI in Smart Manufacturing

IoT and AI have long been used in the manufacturing sector, with many companies and industrial facilities implementing these cutting-edge technologies to build products. These developments have revolutionized the mass manufacturing of items and increased the output of several sectors. IoT may collect information from several units and send real-time data, improving performance and reducing effort.

Advanced analytics allows manufacturers to pinpoint potential failure sources and take the necessary countermeasures. The repair of machinery may be planned before any issues because AI's real-time monitoring offers complete insights into the operation. That's vital because it detects small, early errors before they turn into giant, costly disasters.

Industrial IoT Applications of AI

Like most things with AI, we can talk about many applications and use cases. But, these are the top ones that we believe to be more relevant to Industrial IoT


By gathering motion data from people, AI can manage autonomous (IoT) equipment like robots. This makes it possible for robots to understand their environment and efficiently use all their parts to handle complex tasks without the need for human supervision.

For instance, you may develop a framework that enables robots to move and carry out their tasks like a normal factory worker. This innovation has several benefits, enabling robots to move around the factory floor securely and effectively or handle delicate objects without damaging themselves or the products.

Inventory optimization

Inventory management is another use case that can greatly enhance your operations. AI and IoT take this to a whole new level in Industry 4.0, making inventory management smart. Using trends in historical data, AI-powered inventory management can always keep stock at the required level while not exceeding any budgetary or storage limits.

While it's great to get such deep insights with real-time data, some Industry 4.0 companies take the meaning of "smart" to another level by using robots and IoT-powered infrastructure to monitor and restock the inventory, significantly boosting their productivity and minimizing unexpected costs.

Smart thermostats                                             

While smart thermostats are popular in residential applications, there’s no reason to ignore their benefits in industry and manufacturing.

Using historical data about personal preferences, you can get your phone to track and regulate a room's temperature remotely, making the entire space comfortable for all employees. This all happens through a line of communication between IoT sensors and AI that control the thermostat.

For the AI system to function and reach an accurate estimation, it requires a lot of data. IoT gathers this information through sensors placed throughout the factory. These data are sent to the AI cloud for evaluation and processing. The thermostat gets commands from the AI to better adjust the temperature.

Market Prediction

AI and IoT applications in Industry 4.0 are not just limited to the factory floor. Market algorithms may analyze consumer data trends and other variables to foresee demand and adapt to a constantly shifting market, helping manufacturers adjust their output and inventory.

Another powerful area is social listening where companies can learn what consumers think about items, which could impact the entire production process from design to features and cost. With this data, businesses are ready to plan ahead and adapt to changes faster than other competitors. Such projections may help with cost management by optimizing stock levels, personnel needs, and energy usage. 

Smart Retail Security

It may be a bit harder to connect this one to other items on the list, but it’s worth mentioning anyway. The majority of retail establishments use high-tech video systems that use face recognition to identify clients as they arrive. With the help of AI, it is now easy to identify and classify particular qualities in every customer or employee that can boost marketing efficiency.

Product choices, sex, age, and a host of other factors that influence customer behavior are just a few examples. As a result, decision-makers might use advertisements that focus on a certain demographic or simplify the admission procedure for customers.

AI & Industrial IoT: The Future

So, there you have it. This is just a thumbnail sketch of how AI and Industrial IoT can reduce costs, minimize errors, and boost efficiency. The applications are simply too good and diverse to ignore. 

From automation, quality control, and predictive analytics to market prediction, standardization, and robotics, AI and IoT solutions have all the hallmarks of a revolutionary stage in Industry 4.0. 

This is a stage where businesses, including yours, can significantly benefit from such changes and guarantee their survival in the fast-moving market. But, you need help along the way and we at Lanars can help you. Our expert team is by your side to give you the perfect blend of AI & IoT solutions. You just need to get in touch and let us start right away!