In today’s connected world, we are surrounded by home monitoring networks, fitness trackers and other smart systems. They all use an IoT platform to keep us up to-date with the current temperature in our house or the number of steps we have taken in a day. Is there a way to use this incredibly smart technology to improve ESD Control? Let’s take a look!
1. Internet of Things (IoT)
The Internet of Things (IoT):
- Connects “things” in the physical world to the internet using sensors.
- Collects data for these “things” via sensors.
- Analyses the collected data and provides a deeper insight into the “things”.
This is a very broad and vague definition but then IoT is used everywhere today – from medical devices to vehicles, homes etc.
“The Internet of Things (IoT) is the network of physical devices, vehicles, home appliances, and other items embedded with electronics, software, sensors, actuators, and connectivity which enables these things to connect and exchange data, creating opportunities for more direct integration of the physical world into computer-based systems, resulting in efficiency improvements, economic benefits, and reduced human exertions.” [Source]
The history of IoT [Source]
The Industrial Internet of Things (IIoT) applies specifically to manufacturing and industrial processes.
It has slightly different requirements compared to consumer IoT products but the principle is the same: smart machines (incorporating various sensors) accurately and consistently capture and analyse real-time data allowing companies to pick-up problems as soon as (or even before) they appear.
2. Industry 4.0
IoT helped push the 3rd industrial revolution (machine automation) one step further. “Cyber Physical Systems (CPS) dominate the manufacturing floor, linking real objects with information processing, and virtual objects via the internet. The goal is to converge Operational Technology (OT) and Information Technology (IT).” [Source]
The 4th industrial revolution is also referred to as “Industry 4.0”. “At the very core Industry 4.0 includes the (partial) transfer of autonomy and autonomous decisions to cyber-physical systems and machines, leveraging information systems”. [Source]
Industry 4.0 as fourth industrial revolution [Source]
So, how can companies use the power of IoT and create accessible, real-time feedback on the status of their ESD Control Protected Area (EPA) and ESD control items?
3. IoT in ESD Control
ESD damages can be extremely costly – especially when it comes to latent defects that are not detected until the damaged component is installed in a customer’s system. Conventional ESD control programmes incorporate periodic verification checks of ESD control products to detect any issues that could result in ESD events and ESD damage. The problem is that ESD control products (and the EPA as a whole) are not constantly monitored.
Take an ioniser for example: if a company uses ionisation to handle process-essential insulators, the ionisers need to be fully reliable at all times. If an ioniser passes one check but is found to be out of balance at the next, the company faces a huge problem: nobody knows WHEN exactly the ioniser failed or if contributed to a charged insulator potentially causing ESD damage.
The Industry 4.0 IoT platform will be a game changer when it comes to creating a reliable and dependable ESD control programme. Sensors collecting vital ESD information like field voltage, Electromagnetic Interference (EMI), temperature, humidity etc. in an EPA will help detect potential threats in real-time allowing supervisors to take action even before an ESD threat occurs. Here is a (by no means exhaustive) list of advantages, IoT can bring to ESD Control:
The day in an EPA can be busy. Taking the time to capture and record measurements of ionisers, wrist straps, work surfaces, automated processes etc. can be disruptive and is prone to errors. IoT allows data to be collected automatically without any input from users. This helps to increase the accuracy of data and allows operators and supervisors more time focusing on their actual jobs.
SmartLog Pro®: the SMART Access Control System – more information
Supervisors have all the essential data in one place right in front of them and are able to make informed decisions; they can provide feedback and give suggestions in case of an ESD emergency. IoT allows to pinpoint areas of concern and prevent ESD events.
IoT continuously monitors processes and provides a real-time picture of them – no manual checks required. If a potential threat is detected, warnings will show-up immediately. There is no need to worry about potentially damaging sensitive devices because the next scheduled check of ionisers, wrist straps etc. has not been completed yet.
The number one reason for adapting an ESD control programme is to reduce costs by:
- Enhancing quality and productivity,
- Increasing reliability,
- Improving customer satisfaction,
- Lowering repair, rework and field service costs and
- Reducing material, labour and overhead costs.
IoT pushes all of the above even further
- Reduced workload for operators: Data is collected remotely without any input from users. Operators are not disrupted in their day-to-day activities.
- Reduced workload for supervisors: Supervisors don’t have to collect and analyse data from personnel testers, field meters, monitors etc. The system does it for them and will highlight any issues.
- Further increases in productivity and cost reductions: An ESD Programme can be managed better and with fewer resources.
Static Management Program (SMP): the next generation of ESD Process Control – more information
IoT will no doubt change ESD control and the way EPAs are monitored. Quantifiable data allows companies to see trends, become more proactive and improve the efficiency of their ESD process control system. IoT will support organisations’ efforts to make more dependable products, improve yields, increase automation and provide a measurable return on investment. Not only will this benefit users and supervisors, but the company as a whole.
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Bill McCabe: Quick History of the Internet of Things..
Margaret Rouce: industrial internet of things (IIoT)
Michelle Lam: ESD Control in the World of IoT
Ian Wright: What Is Industry 4.0, Anyway?
Pascal Kriesche: Humans vs. machines – who will manage the factory of the future?
Industry 4.0: the fourth industrial revolution – guide to Industrie 4.0