Case Study · IoT + Analytics
Machine Health Monitoring
Continuous machine condition monitoring with predictive alerts for maintenance planning.
-55%
Unplanned breakdowns
-22%
Maintenance cost
12
Machines monitored
Days ahead
Alert lead time
The Problem
What the plant was facing
Critical machines were maintained on a fixed calendar schedule regardless of actual condition. Unexpected breakdowns still caused hours of downtime, and planned maintenance was often unnecessary work.
Our Solution
What we engineered
- Sensor package: vibration, temperature, motor current on critical machines
- Edge gateway with baseline learning and threshold alerts
- Health dashboard showing per-machine condition indicators
- Predictive alerts routed to maintenance team's phones
- Maintenance history log tied to each machine
Tech Stack
Hardware & software used
Vibration & temp sensorsPLC I/OIoT gatewaySCADA / web dashboardAlerting engine
Gallery
On-site & control room
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