article · Engineering Science & Technology Journal
Intelligent monitoring systems combine internet of things sensors, artificial intelligence, machine learning, and big data analytics to oversee modern manufacturing environments. These systems gather extensive data across production lines and machinery to provide real-time operational insights. By analysing patterns, they detect anomalies, support predictive maintenance to foresee equipment breakdowns, and enable condition-based maintenance that extends machinery lifespans while reducing unplanned downtime and upkeep expenses. Furthermore, continuous oversight allows these systems to identify quality deviations and autonomously adapt process parameters, keeping defects low and meeting quality targets. Looking forward, the incorporation of edge computing promises faster localised data processing, while robotics integration supports autonomous operations. Augmented reality is also anticipated to supply intuitive operator interfaces, positioning these monitoring systems as key drivers of industrial efficiency and process optimisation.
Unplanned equipment breakdowns and defective products create substantial financial losses and delays for manufacturers. By predicting machinery failures before they occur and correcting process deviations automatically, intelligent monitoring helps industrial operations run smoothly, safely, and efficiently. Incorporating these technologies safeguards critical machinery and supports more reliable production outputs.
These systems are targeted at industrial manufacturers seeking to cut maintenance costs and automate quality assurance across production lines. Technologies such as predictive maintenance and condition monitoring are already actively applied within modern manufacturing, whereas enhancements involving edge computing, robotics, and augmented reality represent next-generation capabilities currently in development.
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Intelligent Monitoring Systems (IMS) have emerged as indispensable tools in modern manufacturing, offering real-time insights into production processes, equipment performance, and quality control. This review provides an overview of the current state and future prospects of IMS in manufacturing environments. The current state of IMS in manufacturing involves the integration of advanced technologies such as Internet of Things (IoT), Artificial Intelligence (AI), Machine Learning (ML), and Big Data analytics. These systems collect vast amounts of data from sensors, machines, and production lines, enabling real-time monitoring and analysis of various parameters. By employing AI and ML algorithms, IMS can identify patterns, predict anomalies, and optimize production processes, leading to increased efficiency, reduced downtime, and improved product quality. IMS play a crucial role in predictive maintenance, where they can anticipate equipment failures before they occur, thereby minimizing unplanned downtime and maintenance costs. Moreover, IMS facilitate condition-based monitoring, allowing manufacturers to monitor the health and performance of machinery in real-time and schedule maintenance activities accordingly, optimizing resource allocation and prolonging equipment lifespan. Furthermore, IMS contribute to quality control by continuously monitoring production processes and detecting deviations from desired specifications. By leveraging AI-driven algorithms, IMS can automatically adjust process parameters to maintain product quality standards and minimize defects, thereby enhancing overall product reliability and customer satisfaction. Looking ahead, the future perspectives of IMS in manufacturing are promising, with advancements in areas such as edge computing, robotics, and augmented reality poised to revolutionize manufacturing operations further. Edge computing enables data processing and analysis to occur closer to the data source, reducing latency and enhancing real-time decision-making capabilities. Robotics integration with IMS facilitates autonomous manufacturing processes, while augmented reality technologies provide intuitive interfaces for operators to interact with IMS data in real-time. IMS represent a transformative technology in manufacturing, offering unprecedented levels of visibility, control, and optimization. As technology continues to evolve, IMS are poised to play an increasingly vital role in shaping the future of manufacturing, driving efficiency, productivity, and innovation.. Keywords: Monitoring, System, Intelligent, Manufacturing, Review, Perspectives.
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DOI: 10.51594/estj.v5i3.870
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