The Challenge
Equipment failures arrived without warning, forcing emergency repairs and costly production stops. The manufacturer had sensor data but no way to act on it.
What We Built
An IoT platform ingesting sensor streams with anomaly detection, predictive maintenance scoring and automated alert routing to maintenance teams.
Sensor Ingestion Pipeline
We connected the 8,000 sensors through a secure edge gateway that normalizes vibration, temperature and current readings into a single time series, buffering locally so no readings are lost during a network interruption before they are forwarded to the platform.
Predictive Scoring Engine
Each asset receives a live health score built from historical failure patterns. When a sensor trend crosses its learned threshold, the system flags the asset with a confidence level and the likely fault, instead of waiting for a fixed alarm to fire after the damage.
Alert Routing and Work Orders
Alerts are routed automatically to the correct shift and technician, linked to the asset manual, and converted into a work order with the recommended spare parts. A warning becomes a scheduled task before it becomes a production stop.
Technical Approach
The platform runs on a managed time-series stack: streaming ingestion scales to the cadence of 8,000 devices, models retrain nightly, and the dashboard refreshes asset status on a short interval. Data is encrypted in transit and at rest, and role-based access restricts plant-floor teams to the lines they operate.
Reliability and Scalability
The ingestion layer tolerates device reconnects and backfills gaps, so a network maintenance window does not create holes in the health history the prediction models rely on. New lines can be onboarded by configuration rather than custom coding.
The Result
Unplanned downtime fell 18% in the first six months, and maintenance is now scheduled, not emergency.
Client Feedback
“We finally stopped fixing machines in the middle of the night. The platform tells us which line needs attention this week, so our planning meetings actually have a plan.” — Head of Maintenance
Get a Free Quote
If your equipment already produces sensor data you are not acting on, tell us about your assets and we will map a monitoring approach to your maintenance goals. Share your project details for a free, no-obligation quote tailored to your operation.