Real-Time Factory Equipment Monitoring Dashboard with IoT Sensors
We installed IoT sensors on critical factory equipment and built a monitoring dashboard that collects and visualizes operational status, temperature, and vibration data in real time.
Challenge
The client's manufacturing plant relied on periodic manual inspections by workers to check equipment status, making early anomaly detection extremely difficult. Four unexpected equipment failures occurred over the past year, each resulting in 8-24 hours of production line downtime and significant losses. Additionally, equipment utilization and energy consumption data was not being systematically collected, leaving insufficient data for optimizing production planning and making preventive maintenance decisions.
Solution
We installed temperature, vibration, and current IoT sensors on 30 critical pieces of factory equipment, with data collected in real time via edge gateways to a cloud data platform. The collected data is visualized through a web-based dashboard, giving managers an at-a-glance view of equipment status across the entire factory. An anomaly detection alert system sends immediate notifications via email and chat when temperature or vibration readings exceed defined thresholds. Statistical analysis of accumulated data also provides reporting capabilities that identify degradation trends per equipment unit and predict optimal maintenance timing.
Results
In the six months following deployment, zero unexpected equipment failures were recorded, completely eliminating unplanned downtime. The system detects anomaly precursors an average of 48 hours in advance, enabling a shift to planned preventive maintenance. Overall equipment effectiveness improved from 82% to 94%, and energy consumption visualization contributed to an approximately 12% reduction in monthly electricity costs.
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