Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

IoT in Manufacturing
Digital Learning Handout

Course Title IOT IN MANUFACTURING

Course No(s) ET ZC449/MM ZC449

Credit Units 4
Credit Model 3+0+1 (32 Hours of Class-room Instruction + 96 Hours of Student Preparation)
Content Authors Prof. Manoj Kakade
Version Number 4
Date 24 July 2021

Course Description:

Limitations of existing manufacturing systems, Safe work practices and workplace safety in
manufacturing systems, industrial revolution 4.0 for manufacturing, manufacturing enabled by elements
of Industry 4.0 such as IoT, big data and cloud computing, robotics, additive manufacturing, and artificial
intelligence. Connected factories. Smart devices and smart products. Manufacturing systems connectivity
and networking using IoT. Real-time and multi-source manufacturing information sensing system
using sensors and their management, cyber-physical systems, various connecting devices, data acquisition
devices, communication technologies (WIFI, IEEE 802.15.41), RFID, QR codes, cellular technologies,
protocols, hardware and software (IDE). IoT enabled smart assembly station. Cloud computing based
manufacturing resources configuration method, IoT enabled material handling systems such as smart
trolleys, real time key production performances analysis method, real-time information-driven production
scheduling systems, IoT based prototype manufacturing system, smart devices and control systems for
manufacturing. Smart eyes on shop floor, integrating smart into existing. Programming using IoT. Case
study and implementation. 

Course Objectives:
 To understand current industrial revolution 4.0, the smart manufacturing and its implementation
 To understand the basic architecture of IOT and how IOT helps in increased productivity
 To understand how IOT sensors, automation and data science are transforming individual processes
and improving operational performance throughout the manufacturing enterprises
 To explain how IOT is implemented in other departments and how users can increase efficiency and
productivity in other facilities apart from manufacturing

Text Book(s):
T1 Internet of Things: A Hands-On Approach by Arshdeep Bahga, Vijay Madisetti, University Press
Publication, 2015.
Reference Book(s) & other resources:
R1 Zhang Y. and Tao F., “Optimization of Manufacturing Systems using the Internet of Things”,
1st Edition, 2017, Academic Press (Elsevier), UK.
R2 IoT Fundamentals : Networking Technologies, Protocols, and Use Cases for the Internet of
Things, 1/e by David Hanes , cisco press
R3 Internet of Things and Data Analytics Handbook by Hwaiyu Geng © 2017 John Wiley & Sons,
Inc.
R4 The Internet of Things: Key Applications and Protocols Olivier Hersent, David B. 2 nd Edition,
Wiley Publication
R5 Internet of Things: Architecture and Design Principles Rajkamal. 1 st Edition, Mc Graw Hill

Experiential Learning Components:

1. Lab work: Remote Lab
2. Project work: None.
3. Case study: Yes
4. Work integrated Learning Exercise: None.
5. Design work/Field work: None.

Content Structure:

Contact Hour List of Topic Title Sub-Topics Reference

 Safe work practices and workplace Lecture
safety note
 An understanding of the Seven
Deadly Wastes
1-2 PREREQUISITE
 Industrial Standardized Quality
Systems.
 Troubleshooting industrial
processes and equipment.
 Existing manufacturing paradigms R1 Ch1, R3
INDUSTRIAL and their limitations Ch1, Lecture
3-4 note
REVOLUTION 4.0  Industrial revolutions 1, 2, 3 and 4
 Digital manufacturing
 Forces behind Industry 4.0 (IoT, R1 Ch1, R3
big data, cloud computing, Ch1, Lecture
robotics, additive manufacturing note
and artificial intelligence)
Forces behind
5-6  Connected Factories (What is
Industry 4.0 connected factory and criteria for
connected factory)
 How the current industry is
different from Industry 4.0
7-8 Introduction & Concepts  Introduction to IoT (Definition and T1 Ch1
 generalized form)
 Physical Design of IoT
 Logical Design of IoT
 IoT Enabling Technologies T1 Ch1
IoT Enabling
9-10  IoT Levels & Deployment
Technologies
Templates
 Introduction T1 Ch3
11-12 IOT and M2M  M2M
 Difference between IoT And M2M
 Sensor Technology R5 ch7
 Participatory sensing , Industrial
Sensors, Participatory IoT and Automotive IoT
13-14
sensing, Actuators  Actuators
 Sensor Data Communication
Protocols
 RFIDs, WSN technology
R5 ch7
 QR codes, SMART Sensors
SMART Sensors ,  Parameters to be considered while
15-16
RFIDs selecting Sensor
 Fitting sensors in existing
equipment and machines
 Basic building blocks of an IoT
Lecture
IOT Physical devices & device
17-18 Notes
Endpoints  Microcontroller Architecture ,
General Purpose I/O
 UART Lecture
IOT Physical devices &
19-20  I2C Notes
Endpoints
 SPI
 Aspects of connectivity and
Lecture
networking
Notes
Connectivity and  OSI Model, TCP/IP
21-22
Networking  Ethernet
 Routers, Switches and gateway
devices
 CAN , LIN Lecture
 Modbus Notes
 Profibus
Connectivity and  IEEE 802.15.4
23-24
Networking  Zigbee, BLE
 WLAN
 WIFI
 GSM, GPRS
25-26 Data collection, Storage  Cloud computing paradigm for R5 ch 6
and computing using Data collection , Storage and Lecture notes
Cloud Platform & computing (CH11)
Security Challenges for  Everything as a service and cloud
IOT service models
  IoT Cloud based services examples
 Types of attacks and threats
 Anatomy of IoT Cyber attacks
 Cloud computing based
manufacturing resources
configuration method
R1ch5
 IoT enabled material handling
Data management in R1Ch6
systems
27-28 IoT & Mobile app R1 Ch7
 real time key production
development R1 Ch8
performances analysis method
Lect notes
 real-time information-driven
production scheduling systems
 Mobile app development basics
 IoT Enabled smart trolley R1Ch6
 Smart Shop Floor R1 Ch9
Applications of IoT in
29-30  IoT - Enabled Smart Assembly R1 Ch4
manufacturing
 Smart Inventory Management / Research
Customized Order Management Paper
 Smart Predictive Maintenance Research
 Smart Supply Chain Management / papers
Smart Logistics
Applications of IoT in
31-32  Smart Product Lifecycle
manufacturing
Management
 Smart Material Management /
Smart Asset Monitoring


Evaluation Scheme:

Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session

Evaluation Name Type (Open Weight Duration Day, Date,
Component (Quiz, Lab, Project, Mid- book, Closed Session, Time
term exam, End semester book,
exam, etc.) Online, etc.)
Quiz-1 &2 Online 10% Will be
informed by
EC - 1 theory faculty
Virtual Lab Online 20% Check Link
Below
Mid-Semester Test Open Book 30% 2 hours Friday,
11/03/2022
EC - 2 (AN)
2 PM – 4 PM

EC - 3 Comprehensive Exam Open Book 40% 2 hours Friday,

20/05/2022
(AN)
 2 PM – 4 PM

Syllabus for Mid-Semester Test (Open Book): Topics in Contact Hours: 1 to 16

Syllabus for Comprehensive Exam (Open Book): All topics
Important links and information:
Elearn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the Elearn portal on a regular basis and stay up to date with the latest
announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on the Elearn
portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them through the
course pages on the Elearn portal. Announcements will be made on the portal, in a timely
manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or bound)
is permitted. However, loose sheets of paper will not be allowed. Use of calculators is permitted
in all exams. Laptops/Mobiles of any kind are not allowed. Exchange of any material is not
allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the student
should follow the procedure to apply for the Make-Up Test/Exam which will be made available
on the Elearn portal. The Make-Up Test/Exam will be conducted only at selected exam centres on
the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self-study schedule
as given in the course handout, attend the online lectures, and take all the prescribed evaluation
components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam according to the
evaluation scheme provided in the handout.
 IoT in Manufacturing ET ZC449/MM ZC449 Lab Handout

Contents:

1. Scope of Lab
2. Objective of Lab
3. Learning Outcomes of Lab
4. List of Tasks/Experiments

Faculty SS Kendre
Name, Email
Id& Contact kendres.shankarrao@wilp.bits-pilani.ac.in
Details 7020724344

Scope of the lab

 This will help participants to understand the functioning of Sensors, Participatory sensing, Actuators ,
IOT Physical devices and applications of IoT in manufacturing industry.
 The lab will also provide the opportunity to students to combine IoT physical devices and implement
it to solve Industrial problems.

Objectives of Lab
 To develop skills which will help students to model, connect things (sensors/hardware), analyse,
validate and verify the knowledge of underlying principles of internet of things used in Industry.
 Students will have hands-on experience of applying mechanical, electronics, networking and
computer science knowledge, with the help of remote lab.

Learning Outcome of the lab

 Connecting microcontrollers to the internet and streaming sensor data to cloud.
 Actuation using microcontrollers.
 Interfacing Android mobile with microcontroller based applications.
 To conduct remote experiments using domain knowledge of sensor integration, data acquisition.

List of Tasks/Experiments
1. Implementation of controlling DC motor speed and monitor Gas sensor in such a way if RPM of
DC motor goes above or below a certain level then notification will be sent to competent
authorities and see these variations live on cloud platform.
2. Implementation of controlling process plan parameter such as temperature and initiating
corrective action such as switching on / off DC Fan if the Temperature value goes up a certain
level and also to send notifications via email to competent authorities and see these variations live
on cloud platform.
3. Implementation of monitoring water level of any reservoir using Ultrasonic distance sensor and
send data to cloud and raise an alarm when the water level crosses a threshold level using e-mail
notification
4. Monitoring process plan parameters for vibration, send email if the vibration is detected and
control (Motor ON/ OFF / Bulb ON/OFF) and see these variations live on cloud platform.
5. Implementation of Security system (motion sensor) to detect the person in a restricted area. If
anyone found in that area, sensors will detect and switch off the machine and send email
notification to competent authorities.
6. Implementation of interfacing Sunlight sensor and monitor UV, VIS, IR values live on cloud
platform and send notifications via email to competent authorities about the variations in these
parameters after reaching a certain threshold
7. Monitoring control mechanism (10 Degrees Of Freedom) to detect the unnecessary movement of
equipment and monitor x,y,z values on the cloud platform as well as send the email notification
to competent authorities if the value is above a certain level or below.
8. Monitoring/counting produced items by differentiating using color code and send the counted
products via email notification to competent authorities.