How connected devices are revolutionising manufacturing

26 June 2025 | IMI Norgren

• Automation & Robotics
• Machinery, Tooling, Production- and Safety Equipment

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Learn how connected devices boost manufacturing efficiency and cut downtime, unlocking the potential of Industry 4.0 without costly overhauls.

At first glance, smart manufacturing can appear intimidating.

You might think that the shift towards a connected future and Industry 4.0 needs extortionate capital expenditure to deliver the necessary levels of flexibility and responsiveness.

But that’s not necessarily true – there is another, smarter way.

Instead, you can take an approach that extracts maximum value from your existing plant equipment – without massive costly production line overhauls.

Let’s take a look at how ‘smart components’ are helping OEMs extract value from their existing production lines, improving manufacturing productivity and efficiency – and getting them ready for Industry 4.0.

The growth of connected devices in manufacturing

The number of connected Internet of Things (IoT) devices is growing at a rapid rate, from over 16 billion devices in late 2023 to over 18.8 billion forecast by the end of 2024.

Connected devices bridge the gap between traditional machinery and the digital future, unlocking previously unattainable insights and efficiencies.

Embedded with sensors and connectivity technology, connected devices monitor the condition of components in real time, recommend timely intervention through predictive maintenance, and improve overall plant performance and commercial competitiveness.

Ultimately, integrating connected devices into manufacturing processes allows operators to reduce downtime, save maintenance costs, and achieve their sustainability goals.



How can connected devices maximise value in existing production lines?

When OEMs choose which connected devices to integrate into their existing production lines to maximise their potential value, they need to consider three key factors.

Seamless integration with existing systems

In some applications, such as environments that use programmable logic controllers (PLCs), any new components need to be compatible with the existing protocols. Otherwise, they won’t be able to communicate effectively with the PLC and provide the necessary data.

However, in open-source applications, many components are designed to be compatible with a wide range of existing in-situ components. This allows OEMs to select the most appropriate devices for the given application.

No matter what the application, OEMs should make sure that their devices are:

1. Easy to install, integrate, and use, so that they can minimise disruption

2. Able to provide rapid, relevant, and actionable insights, so that they can see results faster

Modularity and flexibility

OEMs need to choose connected devices with a clear understanding of what they’re trying to achieve. Whether it’s monitoring a specific production parameter, gathering detailed information on components and performance across an entire system, or achieving something in-between, OEMs need to strike the right balance:

> By under-specifying, OEMs risk missing out on the required level of detail, overlooking critical insights and leaving opportunities untapped.

> By over-specifying, OEMs can incur higher financial costs upfront and extract overwhelming mountains of data that they may not have the time, need, or ability to manage.

Instead, a modular system allows OEMs to adapt as their needs evolve. New devices can be added or swapped in as monitoring requirements change, keeping their systems future-proof.

Delivering tangible value

Connected devices always need to provide a clear value to OEMs. As well as minimising downtime, there may be other considerations such as reducing energy consumption, cutting carbon emissions, and optimising specific performance parameters.

Let’s focus on downtime, a critical factor in profitability.

Downtime often eats into production time and, in the process, eats into profit margins too. While completely eliminating downtime is nearly impossible, connected devices can help by providing insights into:

> What issue is causing the downtime,

> Why it happened,

> What remedial action is needed, and

> What parts are required for repairs

These insights help drive better decision-making around component specifications and maintenance, allowing OEMs to reduce the risks of further downtime in future.

Example: Connected devices in compressed air systems

Connected devices do more than just identify problems – they provide actionable solutions that translate into real-world benefits.

One key area where connected devices can add this significant value is in compressed air systems.

One common misconception is that, because air is readily available all around us, compressed air is a free resource. The truth is that compressed air is one of the most energy-intensive utilities in industrial settings, with significant energy going into compressing and processing air ready for use in pneumatic applications.

In fact, in Europe alone, approximately 10% of all industrial electricity consumption goes on producing compressed air. With energy costs rising rapidly, OEMs need to work quickly to make their processes more efficient and minimise these costs.

One major challenge associated with compressed air systems is leaks. Leaks are a common but inevitable result of system wear and tear. They often go unaddressed as they’re difficult to detect, even in facilities where systems are regularly checked.

Connected devices, however, are on course to change this. By rapidly pinpointing problem areas where leaks can occur and impact overall system efficiency and performance, these devices can assess what appropriate remedial actions OEMs need to take for rapid fixes. This provides two key benefits:

1. Immediate energy savings – reducing leaks directly lowers the energy needed for compressed air production.

2. Reduced equipment size – over time, better system efficiency can allow production plants to downsize their compressors, improving long-term financial and environmental outcomes.

The future of connected devices

Connected devices will allow OEMs and operators to monitor performance and optimise their manufacturing environments for years to come.

Ranging from simple onboard screens to complete cloud-based systems accessed via PC, tablets, or smartphones, connected devices provide a ‘single source of truth’ for system performance.

However, it’s vital to look at connected devices not just as data collectors, but as tools for generating meaningful insights.

A trusted systems partner, can recommend the best solutions to specific production needs, with connected devices that deliver intelligent, actionable insights – improving decision-making and operational efficiency.

Stay competitive in a rapidly evolving industrial landscape with connected devices. Reach out today to take your first step toward a smarter, more connected future with us.