Smart Factory IoT Platform
The Challenge
Production lines ran on legacy PLCs with no unified visibility. Maintenance was reactive, energy costs were surging, and leadership lacked real-time metrics to make decisions.
Our Solution
We deployed edge gateways with secure MQTT connectivity, built a streaming ingestion pipeline, and layered digital twins plus alerting dashboards. Predictive models flag anomalies hours before breakdowns.
Key Features Delivered
- Edge anomaly detection with on-device inference
- Digital twins for each production cell
- Role-based dashboards for maintenance, ops, and leadership
- Automated work orders via ServiceNow integration
- Carbon and energy tracking by line and facility
Project Gallery
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Technology Stack
Powered by industry-leading technologies
Business Impact
Maintenance teams now intervene before failures, saving $4.1M annually. Operators monitor OEE in real time, and the sustainability team hit energy reduction targets ahead of schedule.
Project Timeline
Sensor & PLC Audit
3 weeks
Catalogued equipment, communication protocols, and data availability across plants.
Pilot Line Deployment
5 weeks
Installed edge gateways, built ingestion and alerting for a single production line.
Platform Scale-Out
8 weeks
Rolled out across all lines with automated device provisioning and SSO integration.
Optimisation & Training
4 weeks
Ran workshops, tuned models, and launched executive dashboards.
"We finally have one source of truth for operations. The predictive alerts alone paid for the project in six months."
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Proven Track Record of Excellence
Delivering AI-powered solutions to enterprises worldwide with measurable ROI and lasting impact