Client Overview
An international company that builds industrial machinery aimed to move toward Industry 4.0 by adding intelligence to how its products are produced. Yet, due to not being able to see much on the machines and adopting just reactive methods, there were a lot of breakdowns, and costs were going up.
Use of eInnosys’ powerful IoT system enabled the factory to digitize all its assets and gain predictive control of its performance. Machine uptime became 40% greater, and the number of maintenance-related production halts decreased by 25%.
About the Company
Challenges
Lack of Real-Time Equipment Data
There were no predictable signs that the equipment was going to fail beforehand, causing unplanned downtime for operators.
Manual Monitoring & Logging
Since data was entered by humans, errors and slow decision-making became common.
Reactive Maintenance Model
When damages to assets were reported, the company fixed them late, which increased their overall expenses and led to a drop in production.
No Unified Asset Visibility
Machines from various OEMs did not have a common way to track data.
Our IoT-Driven Solutions
Sensor Integration & Edge Device Setup
We installed IoT sensors into old machines to track vibration, temperature, how much power they use and their running hours. Edge devices filtered and processed data in real time and then sent it to the cloud.
Predictive Maintenance Engine
We spotted potential equipment malfunctions through timeline analysis and alert detection and carried out scheduled preventive measures.
Centralized IoT Dashboard
The role-based control center we built enabled plant managers to check the performance and functioning of all the machines.
Automated Alerts & Escalations
Employees were alerted about downtime issues by receiving messages automatically via SMS, email, or the platform dashboard.
Tech Stack
IoT Platforms : Azure IoT Hub, AWS IoT Core
Programming : Node.js, Python
Device Management : MQTT, OPC-UA
Data Processing : Azure Stream Analytics, AWS Lambda
Dashboards : Grafana, Power BI
Business Impact
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