Edge Devices: A Practical Tool for Small and Mid-Sized Manufacturers
by Shawn Furman
Director, Automation and Manufacturing Technology Strategy
Manufacturers Resource Center
For many small and mid-sized manufacturers (SMMs), the idea of “Industry 4.0, 5.0, etc.” or “smart manufacturing” can sound intimidating—something only big plants with huge budgets can afford. But one technology that’s proving accessible and highly valuable, even for smaller facilities, is the edge device.
What Is an Edge Device?
An edge device is simply a piece of hardware—like a smart sensor, an upgraded PLC, or a small computer—that sits right on your production floor. Instead of sending all your machine and process data to the cloud or a central server for analysis, an edge device can collect, analyze, and act on that data right where it’s generated.
Think of it like having a skilled operator standing at the line, spotting issues immediately and making quick adjustments, instead of waiting for reports to come back hours or days later.
How Can SMMs Use Edge Devices?
Here are some real-world applications that don’t require a million-dollar budget:
- Quality Checks in Real Time
- A vision sensor can flag a defective part or color mismatch before it gets packaged, reducing scrap and rework.
- Predictive Maintenance Made Simple
- A vibration or temperature sensor on a motor can warn you of bearing wear, allowing you to schedule maintenance before a costly breakdown.
- Energy Savings
- Edge devices can monitor electricity or compressed air use and identify leaks or waste that drive up utility bills.
- Process Consistency
- For operations like mixing, coating, or filling, edge devices can automatically adjust flow rates or speeds to keep product quality consistent.
- Machine Connectivity Without Full System Overhaul
- Edge gateways can connect your older, “dumb” machines to modern dashboards without needing to replace expensive equipment.
Why Should SMMs Consider Them?
- Quick Wins – Many edge devices can be installed on a single line or machine, showing results within weeks.
- Low Cost of Entry – You don’t need to digitize your entire factory; you can start small and scale up as you see value.
- Reduced Downtime – Catching issues early keeps lines running and customers happy.
- Better Decisions – Operators and managers get timely data to make improvements.
- More Secure – Sensitive data can stay on your shop floor instead of going out to the cloud.
Pros and Cons
Pros for SMMs:
- Affordable entry point into smart manufacturing
- Minimal disruption—devices can often bolt on to existing machines
- Quick ROI through scrap reduction, energy savings, or less downtime
- Easier to expand one step at a time
Cons to Consider:
- Some upfront investment in sensors or gateways
- May require training for your team to interpret and use the data
- IT/OT integration (shop floor to office systems) can take planning
- Managing multiple devices across lines can become complex if not standardized
The Bottom Line
For small and mid-sized manufacturers, edge devices offer a practical first step into smart manufacturing. They don’t require replacing your machines or making a massive investment. Instead, they let you start small—installing a sensor here, a gateway there—and begin seeing improvements in quality, uptime, and efficiency almost immediately.
In short, edge devices give SMMs a way to compete with larger players by using data-driven decisions
About the Author – Shawn Furman
Shawn Furman
Shawn, Director, Automation and Manufacturing Technology Strategy, mentors MRC manufacturers to lead and guide them in advanced technologies that enhance quality, boost productivity, encourage innovation, and reduce production time. Today that also includes digital transformation, automation and robotics, and IT integration that enables innovation and smart manufacturing, driving extraordinary outcomes for customers.
Manufacturers who want to learn more and to discuss Process Improvements, Advanced Manufacturing Technology resources and Implementations, please call Shawn at (610) 737-2529 or email him at shawn.furman@mrcpa.org