How smart, connected and accurate T&M instruments are driving quality and efficiency in modern manufacturing.

Industrial test and measuring (T&M)  instruments have come a long way from simple analog gauges and manual inspection tools to today’s sophisticated digital systems powered by automation, connectivity, and data analytics. As industries strive for higher precision, efficiency, and safety, these instruments have evolved to meet increasingly complex requirements across sectors such as manufacturing, energy, aerospace, and process industries. Contemporary developments now encompass smart sensors, wireless data transmission, cloud-based monitoring, and AI-driven diagnostics – transforming the way industrial measurements are conducted and interpreted. The Cover Story of this edition explores the journey of these critical tools, highlighting key milestones in their evolution and the latest innovations shaping their future. So what is the current maturity level of test & measurement practices in industrial environments such as manufacturing or process industries?

“The maturity level of test and measurement (T&M) practices in industrial environments such as manufacturing and process industries in India is currently in a transitional phase, moving from traditional, manual methods toward more digitally integrated and data-driven approaches,” says Dr Hemal Desai, Vice President – Marketing, Endress+Hauser India. “Even though the adoption is fragmented, there is a growing awareness about improving testing maturity. Digital technologies like Industry 4.0 and regulatory requirements are driving the adoption of T&M practices,” he adds.

For Jagdish Pranami, Associate Vice President, Electrical & Instrumentation, SRF Limited, the maturity level of T&M practices in the industrial environment varies widely, depending on the industry, organisation, and technological adoption. However, many industries are moving towards more structured and optimised testing methodologies. Several models, such as the Test Maturity Model (TMM) and Test Process Improvement (TPI) frameworks, help organisations assess and improve their testing maturity. These models define different maturity levels, ranging from ad-hoc and reactive testing to optimised and predictive testing. “In manufacturing and process industries, testing maturity is often influenced by factors such as: automation & digitalisation, standardisation & compliance, and data-driven decision making,” he suggests.

Adding a different perspective, Konrad Stegemann, Senior Global Technical Marketing Manager – Automotive Solutions and Products, NI Test & Measurement at Emerson, states that the maturity of T&M practices varies significantly across sectors and geographies. “In highly regulated industries like aerospace and pharmaceuticals, T&M is deeply embedded in both R&D and production workflows. However, in many manufacturing and process industries, T&M is still evolving from manual, siloed practices to more integrated, automated, and data-driven approaches,” he explains. Speaking of the NI/Emerson approach, Konrad says, “We’re seeing a growing shift toward software-defined test systems that offer openness, flexibility, and modularity – core strengths of our platform. This shift is helping companies move from reactive testing to proactive quality assurance, enabling faster time-to-market and reduced cost of quality.”

Every industry needs T&M equipment since it is needed to validate the performance of its production process, and the end products as well. So what are the most pressing challenges companies face today in implementing effective T&M solutions?

According to Shyam Warialani, Certified Independent Director, Saw Process Solutions, the most pressing challenges facing the T&M industry may be listed as:

·         Lack of measurement control: If one person performs inaccurate measurements, product quality can be compromised. This will lead to defective parts being mixed with good parts, the result will be a worse yield.

·         Lack of good, smart, repetitive T&M instruments: The test and measurement instruments deployed in industries are either manual, not calibrated from time to time, and there is lack of training for people using them, etc. 

“The most pressing challenges are inadequate focus on quality, and lack of adequate test and measurement instrument budgets. Also the datasets are not integrated with systems to analyse and interpret for preventive and proactive steps. There must be smart test instruments deployed which transfer the data from the instruments to the PC, data logger, or control system wirelessly and compare with Master Data, as this could help in inspection, and quality control in great many ways,” says Warialani.

“Many of the existing enterprises run on the older technologies, where their compatibility with the modern measurement technologies or communication protocols would be a challenge,” says Sudarsan Srinivasan, Managing Director, VEGA India Level & Pressure Measurement Pvt Ltd. “However, these enterprises are not old enough to replace their existing technologies, which would need high capital investments. Hence, the pace at which these enterprises integrate the latest technology is slow,” he adds, and also lists two more:

·         Another challenge can be attributed to ‘technology myopia’, which is failing to understand the long term advantages of implementing the latest measurement solutions. Sometimes enterprises get entangled in a web of cost vs. value perception and fail to recognise the latest measurement solutions as strategic enablers.

·         Cybersecurity is another challenge that’s grabbing attention. As the demand for IIoT networks increases, being able to use secure measurement data all time is now one of the most important requirements of all the industries.

“Companies face several challenges when implementing effective T&M solutions, especially in industrial environments, says Jagdish Pranami. Some of the most pressing issues, according to him, include:

·         Inconsistent measurements: Variability in results due to operator error, environmental conditions, or equipment malfunction can lead to unreliable data.

·         Environmental interference: Factors like temperature, humidity, and electromagnetic interference can affect test accuracy, requiring controlled environments or compensation techniques.

·         Equipment limitations: Some test instruments may not meet the required sensitivity, range, or response time, leading to inaccurate results.

·         High initial investment: The cost of advanced automation tools and skilled personnel can be a barrier to adoption.

·         Integration challenges: Ensuring seamless compatibility between T&M systems and existing infrastructure can be complex.

·         Stringent quality & compliance requirements: Industries must adhere to strict regulatory standards, which demand precise and reliable testing. 

Speaking of safety and compliance, what role does test and measurement play in matters of regulatory compliance and safety assurance across critical industries like oil & gas, pharma, and aerospace?

Addressing this important aspect, Dr Hemal Desai quotes the example of the Life Sciences Industry where compliance and safety play a non-negotiable role, and the points he emphasises are:

·         Ensuring Safety & Efficacy: T&M ensures that drugs meet stringent quality standards for potency, purity, and stability. Instruments like HPLC, GC-MS, and spectrophotometers are used for precise chemical analysis.

·         Meeting Regulatory Compliance: Compliance with FDA, CDSCO, and WHO-GMP guidelines mandates validated testing protocols and audit trails. Data integrity and electronic records (21 CFR Part 11) are increasingly scrutinised, making automated and traceable T&M systems essential.

“In addition every measurement must be traceable to national/international standards. Regular calibration of instruments is essential to maintain accuracy, and increasingly, T&M systems are integrated with MES/ERP systems for real-time compliance tracking and reporting,” Dr Hemal Desai elaborates.

According to Konrad Stegemann, in critical industries like oil & gas, pharma, and aerospace, T&M is the backbone of compliance and safety assurance. It ensures that systems meet stringent regulatory standards and perform reliably under extreme conditions. “NI/Emerson’s solutions are designed to support traceability, repeatability, and auditability, which are essential for regulatory compliance. Our systems are used to validate everything from avionics and medical devices to energy storage systems and industrial automation equipment. By integrating test data across the product lifecycle, we help customers not only meet compliance requirements but also gain insights that drive continuous improvement,” he explains.

Shyam Warialani agrees about the vital role T&M instruments play in critical industries like Oil and Gas, Pharma, and Aerospace. “Meteorological measurements play a very important role in Oil and Gas to determine quality of crude, intermediates in refining and petrochemicals. Also, inadequate or inaccurate measurement could lead to environmental issues or health and safety hazards. Also in Pharma, it is important to accurately measure physical properties of bulk drugs, intermediates to ensure world health standards for drugs and pharma,” he emphasises.

In the connected machines and systems era, how are IIoT (Industrial Internet of Things) and edge computing reshaping the T&M landscape?

“IIoT technology in the field instruments  is enabling industries with remote monitoring, predictive maintenance and real-time monitoring of the processes that helps improve the process efficiency and product quality. These technologies are also helping in effective inventory management, and just-in-time replenishments of inventory increasing the overall cost-efficiency,” says Sudarsan Srinivasan. Speaking of VEGA, he says IIoT allows integration of VEGA’s sensors in wider networks, enabling remote monitoring and control of processes. Predictive maintenance features in VEGA’s Pro-line sensors prevent potential disruptions thereby reducing the instances of surprised downtimes. “Solutions like VEGA Inventory Management (VIS) allows users to remotely access important levels, inventory and location data to ensure effective supply chains. VEGA sensors integrated into automated systems can trigger actions based on real-time data reducing potential manual errors,” he explains.

For Dr Hemal Desai, IIoT and edge computing are revolutionising test & measurement by enabling real-time, on-site data analysis and instant anomaly detection. “They reduce latency and reliance on centralised systems, boosting efficiency and responsiveness. Smart sensors and edge AI allow predictive maintenance and adaptive testing in dynamic environments. Together, they ensure continuous compliance, data integrity, and scalable automation across industries,” he notes.

Jagdish Pranami notes that IIoT and Edge Computing are revolutionising T&M by enabling real-time data processing, enhanced automation, and predictive analytics. These technologies are shifting traditional T&M practices from reactive to proactive and intelligent systems. He has listed the key impacts of IIoT and edge computing on T&M as:

1. Real-time data processing: Edge computing allows instant analysis of sensor data, reducing latency and improving response times. This is crucial for applications like predictive maintenance in manufacturing and fault detection in aerospace.
2. Enhanced automation & efficiency: IIoT-enabled devices automate data collection, calibration, and diagnostics, reducing manual intervention. Smart sensors continuously monitor temperature, pressure, vibration, ensuring consistent quality control.

3. Improved scalability & flexibility: Edge computing distributes processing power across multiple nodes, making T&M systems more scalable. Industries can expand testing capabilities without overloading centralised cloud systems.

4. Security & data integrity: Keeping data closer to the source minimises cybersecurity risks and ensures secure transmission. This is vital for chemical, pharmaceutical and aerospace industries, where data integrity is non-negotiable.

5. Cost reduction & resource optimisation: IIoT reduces downtime and maintenance costs by enabling predictive analytics. Edge computing optimises bandwidth usage, lowering operational expenses.

Digital twins have revolutionised test and measurement by creating virtual replicas of physical assets, enabling real-time monitoring, simulation, and predictive analysis. So how do you see the role of digital twins evolving in the context of test and measurement?

“Yes, digital twins are becoming a powerful tool in the T&M toolkit. By creating virtual models of physical systems, engineers can simulate performance, identify potential failures, and optimise designs before physical prototypes are built, says Konrad Stegemann. “At NI/Emerson, we’re integrating digital twin technology into our test workflows to enable model-based testing. This approach allows for earlier validation, reduced development cycles, and more robust systems. A great example is our collaboration with Siemens on a modular digital twin for train systems, where NI hardware and software were used to create a scalable, simulation-driven test environment for rail vehicle development. This kind of integration showcases the power of our open and flexible platform, enabling customers to combine physical and virtual testing environments seamlessly,” he elaborates.

Shyam Warialani believes digital twins will let engineers perform virtual tests on highly accurate digital models before investing in physical prototypes. This reduces the time and cost associated with traditional testing. “By using a digital twin role one can perform virtual behaviour through simulation modules by using test data, ideal requirements and actual conditions. Digital twins can simulate real-time data from physical devices, enabling predictive maintenance and performance monitoring without the need for constant physical oversight. One can achieve early testing, cost efficiency, Risk mitigation and better collaboration,” he asserts.

“The process industry faces the challenge of implementing standardised digital communication all the way down to the field level. Field level data is measured by the field instruments, which are integrated into decision control systems. The digital twins are not just the digital images of a physical sensor, they combine real objects with virtual models. All the relevant information is stored throughout the lifecycle of an instrument,” says Sudarsan Srinivasan. According to him, the biggest advantages of digital twins include all data in one place, easy access and backup and restoration. “This saves time, simplifies documentation and ensures seamless tracking of all the process parameters,” he adds.

The final question to the Panel of Experts was about future developments. Do you foresee a transition from periodic testing to continuous, real-time monitoring in more industries? What are the drivers?

“Yes, there is a clear transition underway from periodic testing to continuous, real-time monitoring across more industries. This shift is driven by the need for predictive maintenance, minimised downtime, and higher operational efficiency,” says Dr Hemal Desai. “Technologies like IIoT, edge computing, and AI are enabling instant data capture and analysis, making real-time insights feasible. Regulatory demands for traceability and compliance are also pushing industries toward continuous monitoring. As systems become more complex and interconnected, real-time T&M ensures faster response to anomalies and supports proactive decision-making,” he points out.

“Absolutely!” says Jagdish Pranami. “The shift from periodic testing to continuous, real-time monitoring is gaining momentum across industries,” he says, and lists the key drivers as:

1. Advancements in IIoT & edge computing

2. Regulatory & compliance demands

3. Cost reduction & efficiency gains

4. Data-driven decision making, and

5. Cybersecurity & risk management.

Konrad Stegemann too concurs with the consensus emerging on this point, saying NI/Emerson is at the forefront of this transition. “We absolutely foresee a transition from periodic testing to continuous, real-time monitoring across more industries. This shift is driven by several factors:

• Increased system complexity and the need for real-time insights

• Demand for higher uptime and reliability in critical infrastructure

• Advances in sensor technology, connectivity, and data analytics

Our solutions enable continuous test and monitoring across the product lifecycle – from design and validation to deployment and maintenance. A key enabler of this shift is SystemLink, our centralised platform for managing test systems, collecting and analysing data, and optimising lab operations. SystemLink helps teams implement intelligent testing by turning raw data into actionable insights – improving efficiency, traceability, and decision-making across the enterprise,” he says.

So does Shyam Warialani, when he says: “Yes, but more than that there will be transition to the measurement of parameters with digital communication to various stakeholders for real time analysis. The measurement could be continuous or periodic but digital transfer through cable or wireless. The drivers for these transitions are better quality products, meeting safety and health norms, avoiding or mitigating risks, cost optimisation, etc.,” he asserts. 

According to Sudarsan Srinivasan, the key drivers for this shift can be attributed to:

1. As the competition in the market has grown, there is greater need for making your product available just-in-time to have a competitive advantage. Realtime data monitoring helps enterprises to ensure proactive maintenance and reduce such downtimes. 

2. Availability of such real-time measurement and monitoring technology has helped fuel this need. For example, VEGA provides low-cost, maintenance-free, and easy to install sensor technology that has found acceptance in a wide range of industries.

3. Many industries have to comply with increasing regulatory norms, where real-time data driven process controls can become a norm.

4. Push for sustainability and environmental norms has also enhanced this transition as the real-time monitoring can reduce waste by optimising the process efficiency and product quality.

“The shift from periodic testing to continuous, real-time monitoring is in the making and many enterprises have started understanding the value in it,” he concludes.

Note: The responses of various experts featured in this story are their personal views and not necessarily of the companies or organisations they represent. The full interviews are hosted online at https://www.iedcommunications.com/interviews)