01 / IOT MONITORING
IoT Monitoring
We connect to the PLCs, meters, and sensors already on your floor and stream their data into dashboards your supervisors can act on. No machine replacement, no line stoppage longer than a lunch break.
What it actually does
Traceability
Every part gets a history: which machine ran it, which operator, which shift, which batch of raw material. When a customer complaint lands, you trace it back in minutes instead of pulling paper registers. The same records satisfy IATF and customer audits without a scramble.
Stack Modbus TCP/RTU polling · barcode/QR scans at stations · PostgreSQL lot genealogy
Automated Downtime Capture
The gateway watches machine run signals directly, so downtime is logged the second a machine stops — not when someone remembers to write it down. Operators tag a reason from a shop-floor screen in two taps. Pareto charts of stoppage reasons update live, per machine and per shift.
Stack Digital inputs / PLC status bits · edge gateway · MQTT event stream · reason-code kiosk
Energy Metering & Condition Monitoring
Panel-mounted energy meters on RS-485 give per-machine kWh, power factor, and load curves. Vibration and temperature sensors on critical motors flag drift before a bearing seizes. Both feed the same time-series store, so energy cost per part becomes a number you can quote.
Stack Energy meters over RS-485/Modbus RTU · vibration + PT100 sensors · TimescaleDB / InfluxDB
OEE Dashboards
Availability, performance, and quality computed from actual machine signals, not end-of-shift estimates. Rollups by machine, line, shift, and plant. The number your morning meeting argues about becomes the number the machines reported.
Stack Grafana or custom Next.js dashboards · shift calendars · target vs. actual rollups
Architecture
Deployment requirements
The plant provides
- Network
- One LAN drop or 4G coverage near the panel room
- Power
- 230V single-phase point per gateway (10W draw)
- PLC access
- Read-only comms port or spare digital outputs
- Panel space
- DIN-rail space for gateway and meters
We install
- Edge gateways
- One per line or per 8–10 machines
- Energy meters
- Class 1.0, panel-mounted, CT-based
- Operator kiosk
- Rugged tablet or 15-inch touch screen per line
- Server
- On-prem mini-PC, or your existing VM
Timeline First line live in 2–3 weeks from site audit. Installation happens between shifts.
The questions plant heads ask.
Hardware is priced per point (machine, meter, kiosk) and quoted after the site audit — the audit itself is free within Delhi NCR. There is no per-user licence, and the software fee is a flat monthly amount you can cancel with 30 days' notice.
Pairs well with
Ask us about iot monitoring.
A short note about your plant is enough — we reply within one working day, or call +91 95990 94602.