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Industry 4.0, which is the latest wave of industrial revolution, is being driven by data. This isn’t so much about general analysis over data, but the scale at which we can collect and analyse it, and how immediate the feedback is. Internet of Things (IoT), for example, is driving this real-time data collection.
The implications of Industry 4.0 are very far-reaching, even impacting signage, which we associate with being an extremely rudimentary, non-digital protocol. But by using IoT sensors, safety signage can come alive and connect to situations as they develop. Interactive hazard signs become responsive nodes.
The anatomy of an interactive sign
Defining a sign as "interactive" in an industrial setting actually has three key components. To understand the baseline from which this technology evolves, Seton have a go to page that reviews standard signage, which is needed as a fail-safe to digital solutions and to pass regulation.
The first component is sensing. Signs are equipped with environmental sensors, which could be detecting gas, temperature, humidity, movement, and much more. LiDAR and infrared, for example, can perceive the immediate surroundings, looking out for dangerous patterns of activity.
The second is connectivity. Protocols like Wi-Fi, LoRaWAN or private 5G are what helps these signs communicate to a central control system. Two-way data flow helps automate and maintain these systems and is a part of broader Industry 4.0 safety solutions.
The third component is a dynamic display. Low-power e-ink screens are ideal for displaying updated text or symbols with minimal energy draw - they can also withstand a power outage to some degree too, because the ink display only requires power to change what’s displayed. But, e-ink isn’t always the best visibility. High-visibility LED displays can be brighter and used for urgent, impossible-to-ignore alerts.
Benefits for proactive risk management
The primary benefit of interactive signs is of course the real-time hazard monitoring. A sign connected to a network of ammonia sensors can instantly switch from a standard warning to an acute toxic gas alert. This could come complete with evacuation instructions the moment a leak is detected. So, the connection between the sensor, which is 10 meters from the sign, is instant and automatic.
The benefit isn’t only what’s displayed, it’s also what’s not displayed. Studies have shown that being overly cautious with many signs can sometimes lead to workers’ brains treating them as white noise. So by not displaying a danger until it’s present, the impact and efficacy of the signage is improved.
Dynamic displays can be used to show universally recognized pictograms that change based on current conditions. Of course, they overcome language barriers in diverse workforces. A second major advantage is direct integration with Manufacturing Execution Systems (MES) and SCADA for superior smart factory risk management. When a maintenance work order is activated in the MES for a specific asset, a connected sign can automatically display a "Machine Locked Out - Do Not Operate" message. This eliminates the risk of human error who might forget to place a manual tag.
Another benefit is the link to predictive maintenance. A sign near a critical motor can display a "Caution: High Vibration Detected" warning based on data from an IoT sensor, or perhaps data from the motor’s own IoT set-up. Potential failures can be flagged early.
Technical requirements for implementation
Deploying interactive signs requires some careful consideration that is different to the usual signage protocols (though these traditional protocols are also relevant). Network infrastructure must not fail, like Wi-Fi, or be overly dependent on APIs which could expire break. Protocols like LoRaWAN are great for large facilities due to their long-range and low-power characteristics.
Power and durability are also necessary, with Power-over-Ethernet being an efficient solution for signs located near existing network drops. IoT security can also become a weak point if not up to date.
The signs themselves ought to be industrially hardened with enclosures rated to at least IP65 so they can withstand dust and water, while the central system itself needs professional implementation and maintenance.
5-step rollout plan
- Step 1: Begin with a formal Hazard and Operability study to identify the operational areas. Find areas where real-time hazard information would be useful, don’t just implement it unnecessarily.
- Step 2: Launch a focused pilot project in a single area, such as a chemical storage room or a zone with automated mobile robots. This can help validate the tech and establish a clear ROI.
- Step 3: Use the findings from the pilot to engineer the necessary network and data integrations.
- Step 4: Execute a phased installation. This must be accompanied by training.
- Step 5: Establish a process for continuous monitoring and feedback to refine the logic and display rules, as well as traditional standards like height placement and colors.
Interactive hazard signs are just one aspect of Industry 4.0, yet the consequences are vast. This is an opportunity to bring intelligence to safety, and harness the data opportunities available in the work environment to its full potential.
