Smart Manufacturing IoT Solution
IoT-enabled system for predictive maintenance and optimization.
The Problem
Unplanned downtime across 6 manufacturing plants was costing $1.2M per hour. Equipment failure patterns were unpredictable, and the maintenance team was entirely reactive. Sensor data existed but was siloed in legacy PLCs with no cross-plant visibility.
Our Approach
We deployed 2,400 edge sensor nodes across all facilities with a custom Rust-based edge runtime for low latency anomaly detection. A central Azure IoT Hub aggregated telemetry into a digital twin model for each piece of critical equipment, with an ML failure-prediction layer that generates work orders automatically before breakdowns occur.
Measured Results
- 78%Downtime Reduction
- 2400+Sensor Nodes Deployed
- $8.4MAnnual Savings
- 6Plants Unified
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