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Create IOT products and solutions – Part 2

In my last article, I have talked about the challenges and oppurtunities of IOT industry. Now let’s talk about building an IOT product and  benefits of it in the market.

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How about building an IOT device?

Now let me also talk a bit about the process of building an IOT product. If you are thinking of building an air purifier, or a thermostat, or some smart lighting solutions for home, you are very likely to hit the first stumbling block as to how to go about the whole process. How to get a 3D design for the device, where to go for a prototype design, and how to get the electronics (the PCB part) done, and how to make the device talk and interact with various other devices like your mobile phone, etc.
 What you need is professional expertise in not one particular field, but many diverse fields. If you are a software engineer with some experience with coding, you will know writing software is not that difficult as all you need is a computer, and you could create wonders just sitting in home or office. Building a real, physical thing can be really tough & challenging. Not only it requires varied set of skill set, but also can cost much more to prototype, and test it out.

Steps to follow before going ahead

For the benefit of newbies to the field, I have listed down the steps generally followed in any IOT product development process.

  • Market Research
  • Conceptualization/Ideation
  • Design
  • Prototype (Schematic Design, Layout)
  • PCB Manufacturing
  • Procuring components & assembly of electronic circuitry
  • 3D printing of casing & outer facade of the product
  • Field Trials
  • Redesign & trials if needed
  • Marketing & Mass manufacturing

Loads of data is generated, but what to do with it?

Due to the large number of IOT devices around, it is quite as well expected that they will generate a huge volume of data. Question is how to make best use of the data captured, or how to make your device react to events triggered by actions of other users, or may be from the device owner himself through a mobile application.

Standards like the MQTT, AMQP, etc are the general protocols used for an IOT device or the cloud to communicate with each other. Both of them work on basic principle of publish/subscribe. The two parties subscribe to events, and whenever there is an update, or an occurrence of the event, the subscribing parties are notified.

Providers like Microsoft Azure, ABM, and AWS have all come up with their IOT platforms making it easy to monitor and control remote devices from click of a button. Being on the cloud, it gives IOT the ability to scale. The data being captured in the cloud can be analysed, and trends studied using Machine Learning algorithms and Artificial Intelligence.

Today it is possible to auto update the firmware of an IOT device without requiring any intervention from the customer.

How IOT will drive benefits for users?

Data generated from IOT devices are being continuously analysed and machine learning models are built to help in predictive analytics. Earlier emphasis was on preventive maintenance in industries, and anywhere else where machines were deployed. We used to ensure regular and timely checkups to ensure our machines are always in healthy state. But now with advancements in technology, based on the data captured, our machine learning prediction models can warn us in advance of a possible impending breakdown. A corrective action can be immediately triggered, and the machine is restored to good health much before breakdown.

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Today IOT driven processes paves the way for improvements in existing processes leading to higher customer satisfaction & safety leading to better profits for businesses. Customers delight and an increasing affiliation are invaluable assets to any business, and when IOT is able to help the business achieve that, its relevance will never be in doubt. No wonder Gartner Research predicts there will be more than 20 billion IOT devices by the year 2020.
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Smart Machines & Smarter Humans: AI in the Manufacturing Industry

We have all witnessed Industrial Revolutions reshape manufacturing, not just once, but multiple times throughout history. Yet perhaps “revolution” isn’t quite the right word. These were transitions, careful orchestrations of human adaptation, and technological advancement. From hand production to machine tools, from steam power to assembly lines, each transition proved something remarkable: as machines evolved, human capabilities expanded rather than diminished.

Take the First Industrial Revolution, where the shift from manual production to machinery didn’t replace craftsmen, it transformed them into skilled machine operators. The steam engine didn’t eliminate jobs; it created entirely new categories of work. When chemical manufacturing processes emerged, they didn’t displace workers; they birthed manufacturing job roles. With each advancement, the workforce didn’t shrink—it evolved, adapted, and ultimately thrived.

Today, we’re witnessing another manufacturing transformation on factory floors worldwide. But unlike the mechanical transformations of the past, this one is digital, driven by artificial intelligence(AI) working alongside human expertise. Just as our predecessors didn’t simply survive the mechanical revolution but mastered it, today’s workforce isn’t being replaced by AI in manufacturing,  they’re becoming AI conductors, orchestrating a symphony of smart machines, industrial IoT (IIoT), and intelligent automation that amplify human productivity in ways the steam engine’s inventors could never have imagined.

Let’s explore how this new breed of human-AI collaboration is reshaping manufacturing, making work not just smarter, but fundamentally more human. 

Tools and Techniques Enhancing Workforce Productivity

1. Augmented Reality: Bringing Instructions to Life

AI-powered augmented reality (AR) is revolutionizing assembly lines, equipment, and maintenance on factory floors. Imagine a technician troubleshooting complex machinery while wearing AR glasses that overlay real-time instructions. Microsoft HoloLens merges physical environments with AI-driven digital overlays, providing immersive step-by-step guidance. Meanwhile, PTC Vuforia’s AR solutions offer comprehensive real-time guidance and expert support by visualizing machine components and manufacturing processes. Ford’s AI-driven AR applications of HoloLens have cut design errors and improved assembly efficiency, making smart manufacturing more precise and faster.

2. Vision-Based Quality Control: Flawless Production Lines

Identifying minute defects on fast-moving production lines is nearly impossible for the human eye, but AI-driven computer vision systems are revolutionizing quality control in manufacturing. Landing AI customizes AI defect detection models to identify irregularities unique to a factory’s production environment, while Cognex’s high-speed image recognition solutions achieve up to 99.9% defect detection accuracy. With these AI-powered quality control tools, manufacturers have reduced inspection time by 70%, improving the overall product quality without halting production lines.

3. Digital Twins: Simulating the Factory in Real Time

Digital twins—virtual replicas of physical assets are transforming real-time monitoring and operational efficiency. Siemens MindSphere provides a cloud-based AI platform that connects factory equipment for real-time data analytics and actionable insights. GE Digital’s Predix enables predictive maintenance by simulating different scenarios to identify potential failures before they happen. By leveraging AI-driven digital twins, industries have reported a 20% reduction in downtime, with the global digital twin market projected to grow at a CAGR of 61.3% by 2028

4. Human-Machine Interfaces: Intuitive Control Panels

Traditional control panels are being replaced by intuitive AI-powered human-machine interfaces (HMIs) which simplify machine operations and predictive maintenance. Rockwell Automation’s FactoryTalk uses AI analytics to provide real-time performance analytics, allowing operators to anticipate machine malfunctions and optimize operations. Schneider Electric’s EcoStruxure incorporates predictive analytics to simplify maintenance schedules and improve decision-making.

5. Generative AI: Crafting Smarter Factory Layouts

Generative AI is transforming factory layout planning by turning it into a data-driven process. Autodesk Fusion 360 Generative Design evaluates thousands of layout configurations to determine the best possible arrangement based on production constraints. This allows manufacturers to visualize and select the most efficient setup, which has led to a 40% improvement in space utilization and a 25% reduction in material waste. By simulating layouts, manufacturers can boost productivity, efficiency and worker safety.

6. Wearable AI Devices: Hands-Free Assistance

Wearable AI devices are becoming essential tools for enhancing worker safety and efficiency on the factory floor. DAQRI smart helmets provide workers with real-time information and alerts, while RealWear HMT-1 offers voice-controlled access to data and maintenance instructions. These AI-integrated wearable devices are transforming the way workers interact with machinery, boosting productivity by 20% and reducing machine downtime by 25%.

7. Conversational AI: Simplifying Operations with Voice Commands

Conversational AI is simplifying factory operations with natural language processing (NLP), allowing workers to request updates, check machine status, and adjust schedules using voice commands. IBM Watson Assistant and AWS AI services make these interactions seamless by providing real-time insights. Factories have seen a reduction in response time for operational queries thanks to these tools, with IBM Watson helping streamline machine monitoring and decision-making processes.

Conclusion: The Future of Manufacturing Is Here

Every industrial revolution has sparked the same fear, machines will take over. But history tells a different story. With every technological leap, humans haven’t been replaced; they’ve adapted, evolved, and found new ways to work smarter. AI is no different. It’s not here to take over; it’s here to assist, making factories faster, safer, and more productive than ever.

From AR-powered guidance to AI-driven quality control, the factory floor is no longer just about machinery, it’s about collaboration between human expertise and intelligent systems. And at Mantra Labs, we’re diving deep into this transformation, helping businesses unlock the true potential of AI in manufacturing.

Want to see how AI-powered Augmented Reality is revolutionizing the manufacturing industry? Stay tuned for our next blog, where we’ll explore how AI in AR is reshaping assembly, troubleshooting, and worker training—one digital overlay at a time.

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