Factory reset

Can AI and IIoT relieve manufacturers from technical debt?​

​When was the last time your legacy systems helped you innovate?

Outdated technology, non-smart assets and technical debt, hinder manufacturing operations by limiting agility and scalability and increasing costs. Nearly 70% of manufacturers say technical debt holds back innovation, while 46% view their current architecture as a barrier to growth. But here's the good news. Manufacturers are embracing emerging technologies like artificial intelligence (AI) and the Industrial Internet of Things (IIoT), which offer a powerful antidote to technical debt, unlocking a new era of operational efficiency.

Let's dive deeper into what this transformation means for the industry.

Legacy systems: An obstacle to innovation
Tec​hnical debt is more than just a technical issue; it's a major roadblock to productivity and innovation. Legacy systems limit production capabilities, drain resources and complicate the integration of new technologies. Furthermore, the next generation of tech-savvy employees seeks opportunities for growth and advancement.​
Into the era of AI and IIoT​
​By integrating AI and IIoT into operations, manufacturers can break free from the limitations of technical debt and pave the way for greater efficiency, accuracy and profitability. Here's how:
  • Predictive maintenance
    Connectivity to assets through various techniques like sensors and PLC, enables the prediction of equipment failures before they occur, reducing downtime and extending machinery life.
  • Real-time quality control
    AI-powered cameras and VisionAI techniques identify defects instantly, helping ensure consistent product quality.
  • Optimized supply chain
    IIoT facilitates enterprise system integrations with OT systems, enabling planning, real-time tracking and streamlining of inventory management. AI enables demand forecasting, reducing the total cost of ownership (TCO) at factories and warehouses.
  • Accelerated product design
    AI turns market insights into actionable design inputs, aligning new products with consumer demands and reducing time to market. AI enables “should be costing" from available product designs, bringing efficiency and cost reduction.
​​By integrating AI and IIoT into operations, manufacturers don't just upgrade; they transform.
Implementation strategies: From planning to execution

​Realizing the full value of AI and IIoT requires more than technology. It demands strategic foresight. Let's take a look at some of the factors:

  • Readiness assessment
    This is a critical stage in the transformation journey, where organizations need to be assessed for such an initiative. Frameworks are available to guide this journey.
  • Focus on business outcomes
    Focusing on driving business value should be critical than simply pursuing technology adoption. Involving business stakeholders is also necessary. 
  • Driving an IT/OT integration strategy
    A clear roadmap with defined milestones for driving the IT/OT integration plan is key to success.
  • Compliance and OT security
    Ensuring the compliance of AI and IIoT systems with industry regulations is fundamental to safeguarding sensitive information and operations. Organizations must also prioritize OT Security while defining the roadmap.
  • Data strategy
    Defining an organization-wide data strategy is crucial. The right strategy enables organizations to gain meaningful and actionable insights, while an inaccurate strategy can put organizations on the backfoot.
But what are the challenges?

​While the potential of AI and IIoT in reducing technical debt is immense, overcoming deployment challenges is crucial to realizing their benefits. Organizations must address:

  • Talent shortages in AI and IoT expertise
  • Interoperability issues between new and legacy systems
  • Cybersecurity risks from connected devices
  • Complexity in scaling solutions across operations
​Success lies in careful planning, cross-functional collaboration and continuous improvement to unlock the full value of these technologies.
What’s next?

​AI and IIoT are no longer optional; they are essential drivers of efficiency and innovation. From predictive maintenance to supply chain optimization, they offer a lifeline for manufacturers weighed down by technical debt. But technology alone won't solve the problem. It takes the right partner to unlock true transformation.

At HARMAN, we bring domain expertise and innovation to help enterprises navigate the complexities of technical debt. With AI and IIoT solutions designed to integrate seamlessly with your operations, we empower manufacturers to stay agile, innovate faster and achieve sustainable growth.

The time to act is now because the future of manufacturing isn't just about efficiency; it's about thriving.

Contact us to start your AI and IIoT journey today

Ashish Kakani

Senior ​Director, Engineering, Industrial Sector
mailAshish.Kakani@harman.com
LinkedIn ashishkakani