The Challenge
A leading manufacturing company faced recurring production line delays due to undetected machine faults. Manual inspections were slow, reactive, and lacked real-time insights—leading to increased downtime, scrap rates, and maintenance costs.
💡 The Solution
We developed a custom IoT-based fault analysis platform that provided real-time monitoring, predictive insights, and automated fault detection across the production line.
Key Features:
- Edge-enabled sensors on critical machines (vibration, temperature, RPM)
- MQTT-based IoT gateway for low-latency data transmission
- Cloud dashboard for fault trend visualization and alerting
- AI/ML models to detect anomalies and predict failure points
📈 The Results
- 🕒 28% reduction in unplanned downtime
- ⚙️ 23% improvement in maintenance response time
- 💰 19% cost savings in equipment repairs and replacements
- 📊 Real-time insights across 50+ connected machines
✅ Impact
The solution empowered the client with data-driven decision-making, improved OEE (Overall Equipment Effectiveness), and created a scalable foundation for future Industry 4.0/5.0 initiatives.
