The manufacturing industry spent 2024 much in the same way it spent 2023: continuing to deal with the fallout from the COVID-19 pandemic and its impact on the supply chain, coping with workforce shortages and exploring the possibilities new technologies bring to the table. Despite the many challenges manufacturers faced over the last 12 months, they also found new ways to maintain and increase capacity; work safely; and fulfill the needs not only of critical areas such as medical devices, but also in manufacturing the everyday products that continued to provide a resemblance of normalcy.
In many ways, the ability to meet these challenges was driven by technology, with capabilities such as automation and remote monitoring and operation leading the way and enabling manufacturers to ramp up operations and keep workers safe and healthy. One of the most important of these has been the Industrial Internet of Things (IIoT), which connects the essential equipment manufacturers utilize on a daily basis. IIoT networks have proven themselves to be indispensable for many manufacturers thanks to the wealth of big data they provide as well as their potential to bring lasting improvements to their operations. Technological advances will continue to power IIoT trends in 2025, with areas including safety, reliability and flexibility set to be key concerns throughout this year and beyond.
Read on for a look at some of the top Industrial Internet of Things trends anticipated for the coming months.
Key innovations in IIoT technology
The past year has brought some exciting new developments that are expected to have a big impact on the way the manufacturing sector uses IIoT technology. For example, edge computing has emerged as a new way for IIoT-enabled machinery to utilize data with greater speed and overall performance. In short, edge computing collects, analyzes and syncs data using on-site IIoT devices before submitting it to the cloud. This not only speeds up the process of analysis, but also ensures only the most relevant information is passed along to the cloud for advanced modeling or use in artificial intelligence algorithms.
Of course, no discussion of technology from 2024 would be complete without touching upon artificial intelligence and machine learning as their own concepts. These have become integrated even more completely into many manufacturing operations, where they have been recognized as crucial for predictive maintenance. By leveraging these technologies, manufacturers can predict with more certainty where and when they need to focus their attention to prevent unexpected equipment failure and the resulting downtime.
Potential industrial IoT trends for 2025
1. Condition monitoring and predictive maintenance
Sensors are behind so many of the advances of Industry 4.0, and they are a key driver in this area. One of the primary benefits of condition monitoring sensors is that the data and insights that they provide can be accessed from anywhere, at any time. This enables remote monitoring and decision-making based on real-time IIoT data, no matter where personnel is located. As technology continues to evolve, condition monitoring and analytic solutions such as Reliability 360® will be the key to eliminating unplanned downtime. Machine learning is being rolled out in many operations as a means of enhancing and improving the level of accuracy these systems produce, as well. Over the next year, it’s expected that analytical tools will continue to be adopted throughout the industry and digital twin technology will be integrated for comprehensive monitoring.
2. Sensor advances and innovations
With the vast strides being made in communications technology, including the long-awaited widespread availability of 5G networking, facilities will be able to install more sensors to collect more data and have even more information upon which to act. One of the most exciting pieces of IIoT news in sensor technology and usage is the ability to gain more context about data points through multiple sensors, painting a fuller picture of operations and allowing for greater insight into unexpected events — and the ability to prevent them. As the technology continues to advance through 2025, sensors will become even smaller and less intrusive, and self-powered and energy-harvesting sensors will become more widespread.
3. Data-driven predictive technologies
Unexpected downtime is, as always, one of the biggest wastes of resources for a manufacturer, cutting into the bottom line, threatening deadlines, and adversely affecting equipment life span and output quality. With remote monitoring developments that bring monitoring closer to real-time than ever before, cloud-based predictive technology made a major breakthrough in 2024. Predictive maintenance is the primary manifestation of these advances, enabling manufacturers to identify potential problems early, schedule downtime when convenient, ensure that parts and personnel are prepared, and keep operations running as planned. In the coming year, there are likely to be further advancements in terms of prescriptive analytics that provide actionable recommendations. As these emerge, humans and AI will become collaborators in the decision-making process.
4. 5G & edge computing
Industrial edge computing means that not only do robots, motors and other machines communicate with the central server, but they also have data processing capabilities of their own. By sending information such as operating conditions or cycle times back to the main server, this equipment on the outermost edge of the network can provide valuable insights that can be used to improve performance. This is expected to become an even greater element of IIoT as 5G networks reduce the restrictions on speed and bandwidth that affected these connections in years past. Many experts also anticipate that AI will be integrated on the edge for smarter devices, and network slicing will offer more customization in terms of connectivity solutions.
5. Fog computing
Cloud computing is critical for enabling the connections that make the IIoT possible. However, there are limitations in terms of transmission and propagation caused by the distance between cloud servers and IIoT networks. However, fog computing offers a solution. This technology relocates intelligence to the edge of the network, where the machinery exists. This enables real-time control as well as enhanced security and greater manageability. It’s easy to see how fog computing in IIoT should become standard practice throughout the industry, especially if 2025 brings increased standardization and interoperability between devices.
6. Digital twins
Remote access is a common thread through most recent IIoT trends, for convenience and productivity as much as for health and safety (which we will discuss in greater depth below). One of the biggest advances in remote manufacturing operations is digital twin technology, which is a digital representation of a physical component or machine in a factory. Through sensors and connectivity, the digital twin is constantly updated to reflect the actual condition, status and performance of the physical piece. IIoT manufacturing technology such as AI enables simulations that can aid in planning and forecasting — all without the need to be on the factory floor, or even on-site. The use of virtual and augmented reality technologies could bring more realism and accuracy to these simulations in 2025, leading to better results.
7. Health and safety
Worker health and safety took on a new meaning during the pandemic, with the need to keep employees distanced whenever possible, and the ongoing concern over the health of those working in the same area. The principles underlying monitoring technologies used for machines can also apply in this area, with the ability to monitor employee locations on the facility floor, track close contacts, and even quickly and easily take and record employee temperatures. Innovative ways of using IoT manufacturing technology to keep workers healthy provide benefits for employees as well as the facility. Some predict that the use of AI may be used to generate individualized risk profiles for each employee, leading to personalized safety solutions rather than taking the one-size-fits-all approach.
8. Flexibility and agility
Supply chain disruptions were one of the main outcomes of the early stages of the COVID-19 outbreak, creating additional pressure on manufacturers scrambling to keep their operations up and running. The data analysis and communication enabled by IIoT advancements provide unprecedented flexibility in areas such as supply chain, enabling manufacturers to be agile in supplier selection, ordering and procurement strategy, and inventory management. The lessons of the past few years will likely mean that these areas remain of great importance in 2025. One of the key ways this could manifest is through the development of enhanced collaboration platforms that enable better communication between suppliers and manufacturers.
9. Cybersecurity
With the expansion of more wireless devices throughout manufacturing facilities, the number of potential threats increases. Hackers have more vectors for attack than ever, and it’s up to manufacturers to take their cybersecurity seriously or risk catastrophic consequences. Fortunately, there are numerous strategies today for addressing cyber threats that can have a significant difference when it comes to protecting your systems. There is no doubt this will continue to be of the utmost concern for most operations in 2025, especially as quantum-resistant encryption technologies are developed.
10. The smart factory
With IIoT technology increasingly being incorporated and adopted, 5G communications are becoming more commonplace. With the above trends taking hold, the era of the smart factory is truly upon us. 2025 may be the year in which the smart factory becomes more of a norm. These trends reflect the ongoing rise of sensor technology and condition monitoring, while taking into account the newfound need for remote monitoring and access, as well as a new facet of worker health and safety concerns. The development of the smart factory could have a tremendous impact by giving manufacturers the capabilities they need to adapt to mass customization demands.
11. AI and machine learning in IIoT
AI and machine learning algorithms have become mainstream, with many industries finding ways to integrate these technologies into their processes. It isn’t hard to see how these can be applied to IIoT systems, and many manufacturers have found ways to integrate AI in predictive maintenance. One of the biggest IIoT trends this year will be the continued growth of AI into every facet of the process. These applications can be used to improve predictive analytics, anomaly detection and automated decision-making. By analyzing information almost instantaneously and learning from past incidents, AI can lead to better results. This is why many predict artificial intelligence could lead to fully autonomous factories in the near future.
12. Sustainability and IIoT
One of the side benefits of IIoT is how it can support sustainability efforts behind the scenes. As systems communicate with each other, IIoT can monitor and optimize energy management as well as reduce waste and improve resource usage. This means IIoT is expected to be a major component of green manufacturing in the coming years. As sustainability metrics continue to hold a place of prominence in the market, it’s anticipated that IIoT technology could be developed specifically for environmental monitoring.
13. Integration with legacy systems
As IIoT continues to take hold throughout the manufacturing sector, one of the biggest challenges is how to integrate with existing systems. Successfully meshing these technologies together will be key to realizing the full benefits of a smart factory, and it takes specialized expertise to yield the best outcomes. This is sure to be one of the most prominent IoT trends in manufacturing as the industry continues to march toward Industry 4.0 and greater digitization. The development of standardized protocols and interfaces will speed this process along a great deal, leading to scalable and modular IIoT platforms.
14. Human-machine collaborations
Having equipment connected through IIoT opens the doors for new possibilities in human-machine collaboration. For example, the use of virtual reality in manufacturing and augmented reality for maintenance are made possible thanks to the real-time information being provided by a factory’s systems. As communication between people and machines becomes more of a two-way street, the potential for enhanced productivity should only increase. AI assistants are expected to gain ground in 2025, with virtual coworkers and advisors becoming commonplace for many roles within the manufacturing market.
Ethical considerations and data privacy
As technology continues to outpace its anticipated usage, many in the industry have become concerned about the potential risks involved. With generative AI becoming more involved in the decision-making process, many manufacturers have concerns about the transparency of how it reaches conclusions. At the same time, the amount of information being collected and shared by industrial IoT systems gives some companies pause as they consider how to safeguard it.
Stakeholders are sure to share these concerns going into 2025, and manufacturers will need to think about the impact industrial IoT technology will have on how they share and secure their data.
Future predictions for IIoT growth
It may be hard to say with any certainty what the immediate future will look like for the manufacturing sector, but it’s safe to say an ongoing digital transformation will be a major element of the year to come. The industry is built on creative problem-solving, and there’s no doubt that an IIoT solution will find its way into a manufacturer’s strategies over the next 12 months.
As a leader in industrial maintenance for over three decades, ATS is ready to help you navigate the 2025 landscape, so you are equipped to take advantage of these IIoT trends now and in the future.
From industrial technologies to industrial maintenance and parts, we have the breadth and depth to be your one IIoT technology source for improved uptime and productivity. Contact ATS for more information.
