IoT and Custom Software: The Future of UK Manufacturing
In June 2024, the UK manufacturing sector represented 8.8% of the nation’s total economic output and employed approximately 2.6 million people, accounting for 7.0% of the workforce. With confidence on the rise, the sector has reported a 1.2% increase in output during the first quarter of 2024—the highest growth rate since 2022. As manufacturers strive to innovate and stay competitive, Industry 4.0 is emerging as a pivotal force in this transformation.
Industry 4.0 is fundamentally changing how manufacturing operates by connecting machines, devices, and systems through smart technology. This connectivity facilitates real-time data sharing, advanced automation, and flexible production processes. At the heart of this evolution is the Internet of Things (IoT), which integrates physical devices, sensors, and machines with software and connectivity, allowing for data-driven decision-making that enhances productivity and efficiency.
David Ritchie, founder and director of Propel Tech, a bespoke software development firm focused on IoT solutions for the manufacturing industry, explains the significance of IoT in this context: “For manufacturers, IoT signifies a shift from traditional methods to data-driven, intelligent operations that reduce downtime, optimise supply chains, improve product quality, and create agile processes that can quickly adapt to changes in demand.”
In today’s factories, IoT devices are integral to daily operations, delivering real-time insights into production processes and equipment performance. Key applications of IoT technology in manufacturing include:
- Smart Sensors: These monitor conditions such as temperature, pressure, and energy use, enabling manufacturers to prevent machine failures and optimise resources.
- Connected Equipment: IoT-enabled machines share performance data, helping reduce downtime and extend machinery lifespan.
- Predictive Maintenance: By analysing IoT data, manufacturers can predict potential equipment failures, minimising unplanned downtime and reducing repair costs.
- Supply Chain Optimisation: Real-time tracking of inventory and materials ensures timely deliveries while reducing stockouts and overproduction.
While IoT devices form the backbone of connected manufacturing, bespoke software solutions are crucial for fully realising the potential of Industry 4.0. Off-the-shelf software often fails to meet the unique requirements of manufacturers, where highly specialised processes demand custom solutions.
Ritchie adds, “Bespoke software developers with manufacturing expertise can anticipate potential challenges, such as interoperability among different IoT devices, and design software that proactively addresses these issues. Custom solutions align with industry standards, reduce operational risks, and ensure manufacturers maximise their IoT investments.”
Bespoke software drives innovation in manufacturing through tailored solutions that integrate seamlessly with IoT devices and existing infrastructure. These custom platforms aggregate data from various sources—including IoT devices, ERP systems, and supply chain tools—into a central dashboard, enabling real-time monitoring and advanced analytics.
Moreover, bespoke software employs machine learning to predict equipment failures, delivering accurate insights that prevent costly breakdowns. As manufacturers evolve, these scalable solutions adapt to new machinery, processes, and objectives, while also providing enhanced security features to ensure compliance with regulations such as GDPR.
As the UK manufacturing sector continues to grow, the integration of IoT and bespoke software stands at the forefront of innovation, driving the future of manufacturing in the country.
