Avoid Wasted Investment: Choose the Right Smart Device for Your Operations

Imagine walking into your home after a long day, and your Nest thermostat has already set the temperature to your perfect level. Your Fitbit has been tracking your steps all day, and while you were out, your Ring doorbell kept an eye on your front porch. These smart devices work seamlessly together to make your life easier, more efficient, more convenient, and more data-driven. Now, imagine bringing that same level of intelligence and automation to your manufacturing operations.

In theory, adding smart devices into your manufacturing operations promises a lot—real-time visibility, automated data capture, tighter quality control. But in practice? It’s easy to end up with a shelf full of gadgets collecting dust. We’ve seen it happen. A flashy piece of tech gets piloted, half-adopted, and then slowly forgotten. Why? Because the device was solving a problem no one actually had.

Choosing the right connected device isn't just about features and specs. It's about solving the right problems. And to do that, you need two things: a clear understanding of the hidden friction points in your operations and a platform that’s flexible enough to help you address them.

That’s where an open platform comes in. It unlocks the full potential of device integration by making it easy to connect your existing systems, tools, and equipment—without relying on custom integrations. Just as importantly, it lets you embed those connections directly into operator workflows, so data flows effortlessly as work gets done.

To get the most out of connected devices and an open platform, you first need to understand where they’ll have the biggest impact. That means identifying the points in your process where inefficiencies are actively costing you time, accuracy, and sanity.

Here are some questions to ask yourself and your team:

Where are people being slowed down or making mistakes?

Look for steps where operators are keying info into spreadsheets, squinting to read labels, or searching through different bins to pick a component. These types of repetitive, tedious tasks not only slow things down, they also increase the risk of errors or missed steps. When work feels cumbersome or frustrating, people are more likely to make mistakes or find ways to avoid the task altogether. Connected devices, like barcode readers, cameras, and bin-picking systems, can transform how operators tackle these tedious tasks.

What absolutely needs to be recorded—but isn’t?

Think compliance, traceability, performance metrics. When data slips through the cracks or is captured inconsistently, you're putting your operations at risk. A connected device can bring consistency and reliability to critical touchpoints.

Where do quality issues recur (over and over again)?

Think about repeat defects, customer complaints, or rework that seems to come out of nowhere. Are there steps in the process that rely too heavily on memory or manual checks? A smart device might not solve the root cause, but it can add a layer of verification that prevents errors from slipping through.

What data would change the way you work—if only you had it?

This is where smart devices shine: delivering insights from the edge. Imagine knowing machine uptime in real time, automatically tracking environmental conditions, or seeing exactly where a product sits in the process.

Mapping these friction points helps you focus your investments. The goal isn’t to add more technology for the sake of it—it’s to remove barriers to better work.

Once you know where a smart device can make a difference, the question becomes: which device will make that difference? Not all devices are created equal, and not all of them will work in your environment. Here’s what to consider before you commit:

1. Fit for Environment and Workflow

Will it actually work where you need it? A sleek sensor won’t do much good if it can’t survive your shop floor or if it interrupts your team’s rhythm. Make sure the device is rugged enough for the real world and can be integrated into daily operations without creating friction.

Consider ratings and build quality when selecting devices. IP65-rated barcode scanners, like the Honeywell Granit or Zebra DS3600, are built to withstand the demands of industrial environments—dust, drops, and temperature swings included. Despite their rugged design, they’re easy to use: a single trigger pull lets operators quickly capture barcodes, streamlining traceability and removing the need for manual data entry. It’s a rugged, high-performance solution that fits right into fast-paced workflows without getting in the way.

2. Ease of Use and Adoption

If it’s not intuitive, it won’t get used. Plain and simple. Look for tools that require little to no training, make people’s lives easier, and feel like a natural extension of the job—not a new system to learn.

Most operators already know their way around common tools like scales and printers. That’s what makes devices like a Mettler Toledo scale or a Zebra printer ideal candidates for quick, low-friction wins. They're familiar, but now they’re connected. Plug them into your process to automate weighing or streamline labeling, and you’ve got reliable upgrades that fit directly into existing workflows and deliver immediate value without a steep learning curve.

3. Data You Can Trust (and Use)

The value of a smart device lies in the data it captures, so make sure it’s accurate, consistent, and ready to drive action. But it’s not just about quality; it’s also about connectivity. Can the data flow into your existing systems without custom development or workarounds?

Devices with native integrations or pre-built drivers—like Tulip’s Edge Drivers—offer a fast path to reliable, high-performance connectivity. They reduce integration overhead and ensure that the device communicates cleanly with your software stack.

And if a pre-built integration isn’t available, does the device support open, industry-standard protocols like OPC UA, MQTT, or REST API? If so, it’s easy to configure communication through an edge device and get that data into your operational platform where it can be used to improve processes.

4. Scalability and Support

The best devices aren’t one-trick solutions. They’re building blocks in your composable solution. A smart investment today should be able to scale with your operations tomorrow — whether that means expanding to other lines, solving adjacent problems, or rolling out across multiple sites.

Look for devices that are versatile or easily reconfigurable as your needs change. For example, Mitsubishi Vision sensors and Cognex In-Sight vision systems can handle everything from defect detection to optical character recognition (OCR), enabling a single device to support a wide range of quality and traceability use cases. Consolidating functionality in this way helps reduce the number of devices on the floor, streamlines maintenance, simplifies training, and keeps your future deployment options open.

Scalable devices aren’t just cost-effective, they’re strategic. They grow with you, adapt to new challenges, and help ensure that your investment remains relevant over time.

Smart devices can unlock tremendous value on the shop floor, but only when they’re solving real problems in the right places. The risk of making the wrong choice is real: shelfware, wasted budget, frustrated teams. But if you start by identifying operational friction, you can end with devices that are easy to adopt, built for your environment, data-ready, and scalable. You’re not just buying hardware. You’re laying the foundation for more connected, efficient, and adaptive operations.

So don’t chase features. Focus on fit. The right device doesn’t just collect data—it drives action, saves time, and grows with your business. Start small. Think big. Choose smart.