Navigating Industry 4.0 in metals manufacturing

Sparking advancements in metals manufacturing

The manufacturing sector has undergone significant transformation through automation over the past decades. While automation itself isn’t new, the mindset around its implementation has generally evolved, resulting in progressive advancements. Earlier generations of automation using relays, repetitive hardware, and electrostatics have evolved to advanced automation of functions, such as handling information, task processing, and assembly, often requiring minimal human intervention.

The metals industry—a key player in the supply chains of sectors such as construction, automotive, aerospace, and electronics—has reaped significant benefits from these advancements. The industry is now integrating its operations with smart automation to help enhance precision, reduce waste, and minimize environmental impacts. These strategies will likely remain important as the industry adapts to global economic shifts and the growing demand for efficiency, driven by tech advancements, regulatory concerns, and industrial sustainability goals.

Sensors for manufacturing environments

Sensors play an important role in monitoring the manufacturing process across industries. Intelligent sensors can be highly precise and can gather and transmit data to central cloud computing systems for analysis, facilitating the implementation of Industry 4.0 digital decision-making. Both human and computer-based decision-makers may access and track these results, leading to informed decision-making. Download our report for a deeper dive into the use cases for intelligent sensors.

Sensors for machine monitoring

Sensors may be used on specialized applications to monitor and understand the “normal” signature of an output of the whole machine. The sensor algorithm would understand higher baselines as faults, making it much easier to analyze deviations from the machine properties and maintenance concerns. This would allow for predictive or preventive measures before total failure.

A metal manufacturing use case

At one of Europe’s largest steelmaking sites, specialized sensors and monitoring software provide important insights into operations. Electric signature analysis helps the team understand the performance of DC converter cells in harsh conditions by identifying latent issues and maintaining baseline activity in the manufacturing process. This proactive approach ensures planned, well-synchronized factory stops, supporting broader implementation of predictive maintenance efficiency.

The journey from interconnected

Sensors can transition from individual tech to integrated networks, enhancing manufacturing insights and process accuracy. This network approach allows for holistic observation of data and comprehensive environmental monitoring. However, scaling these sensor systems requires adequate network connectivity to avoid excessive costs and switching errors, emphasizing the need to consider the full network infrastructure in deployment strategies.

Connecting the dots: 5G on the factory floor



Sensors have evolved from stand-alone units to integrated networks, significantly enhancing the precision and efficiency of metals manufacturing processes. Some key benefits and considerations prior to integration include:

• Improved insights: Networked sensors provide a more comprehensive view by cross-validating data and monitoring environmental conditions.
• Process accuracy: Integrating multiple sensor types can help improve the accuracy and reliability of manufacturing feedback systems.
• Scalability concern: Effective scaling will likely require robust network systems to avoid increased costs and inefficiencies.
• Infrastructure readiness: The entire manufacturing network infrastructure should be considered when implementing advanced sensor systems.

Looking forward: Next steps with advanced sensor and 5G technology



The integration of sensors and 5G connectivity isn’t just a positional upgrade—it’s an important evolution already underway in the metals industry. Strongly networked factories integrated with AI risk-assessment software represent what’s next. A major goal of manufacturers is leveraging technologies like 5G to improve quality and boost throughput. Wide-scale deployment of smart manufacturing is paving the way for more synchronized, efficient operations that can boost product quality.

If you’re ready to explore how these innovations can empower your business and its operations, set up some time with our industry leaders to discuss how sensors and 5G technology can move your company forward.