The Impact Of Smart Sensors On The Future Of Manufacturing

Within a manufacturing environment, smart sensors can be applied to equipment platforms to help with quality control and monitoring. Smart sensors are capable of converting workhorse machines into intelligent devices that can perform independently. The advancements in sensor technology have attracted future-minded manufacturers and helped them improve operational efficiencies. What follows are some of the major functions of smart sensors and how automation technologies can help manufacturers make substantial growth in a competitive environment:


Lean manufacturing techniques are used to reduce waste and variability in the production processes and improve the quality of products. However, factory managers need to apply a more granular approach to troubleshooting and rectifying process flaws. Companies have to learn how to make business decisions based on data. How can smart sensor technology help companies in this respect?

Smart sensors connect various operating systems and enable different machines to communicate and make intelligent decisions. As compared to traditional old-fashioned sensors, smart sensors use microprocessors to customize outputs and provide interpretive data while ensuring reliable results. The reliable data and effective machine-to-machine communication allow factory managers to make educated choices about their operations.

Equipment failure predictions

Sometimes manufacturers have to cut operations and maintenance budget in order to stay competitive and profitable. Advanced sensors enable manufacturers to reduce unexpected and unnecessary maintenance, downtime, and premature replacement of parts. Timely detection of operational issues leads to reduced downtime. An effective monitoring of production machines minimizes costs associated with machinery breakdown.

Sensors enable IoT

Technology to materialize effective data collection is key to smart factory environment. Smart sensors play a key role in developing IoT applications for manufacturing as they streamline connectivity and analytics. Smart sensing technology have already transformed the way manufacturers implement IoT. Smart sensors are at the heart of industrial IoT. They identify objects, locate them, and generate data regarding their environmental conditions which is critical throughout the supply chain and manufacturing.

The complexity of modern production processes often demands multiple sensing technologies to meet manufacturing needs. A combination of monitoring systems is ideal when managers have to track down multiple factors such as temperature, pressure, vibration, humidity, altitude, motion, maintenance, etc. Companies have to develop new applications to make a good use of all the big data that intelligent sensors can generate.

The need for automation and sensor technology can vary from business to business. How can you determine whether or not your production processes require smart sensors? Understanding the cost of sensor integration into an existing system and the consequence of an evolving workforce will help you determine whether switching to smart sensors is appropriate for you. You can consult an automation engineering company to figure out technologies that can improve operational efficiencies and, consequently, your profitability.

About Us

BP Automation is an automation engineering company in Canada where we design and manufacture custom sensor technology for the manufacturing industry. We also manufacture a comprehensive range of custom machines and engineered solutions which include automated welding systems, material handling equipment, robotics, electrical control systems, and metal fabrication systems. Reach us for a free consultation and we will be happy to analyze how our diverse engineering capabilities can resolve your complex manufacturing problems.