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🏭 Manufacturing
Smart Manufacturing with IoT & Predictive Maintenance
Implementing Industry 4.0 solutions with IoT sensors and AI-powered predictive maintenance, reducing downtime by 80%.
Project Overview
AutoParts Manufacturing, one of India's largest automotive component manufacturers, was facing significant losses due to unplanned equipment downtime. They needed a smart factory solution that could predict failures before they happened and optimize production efficiency.
The Challenge
- Unplanned downtime costing $50K+ per incident
- Reactive maintenance causing production delays
- No real-time visibility into equipment health
- Energy wastage from inefficient operations
- Quality control issues from machine degradation
- Legacy equipment with no digital connectivity
Our Solution
- IoT Sensor Network: 1000+ sensors monitoring vibration, temperature, pressure, and power consumption
- Predictive Maintenance AI: ML models predicting failures 2-4 weeks in advance with 94% accuracy
- Digital Twin: Real-time virtual representation of factory floor
- Energy Optimization: AI-driven scheduling for minimal energy consumption
- Quality Analytics: Computer vision for defect detection
- Mobile Dashboard: Real-time alerts and insights for plant managers
Results
80%Less Downtime
$500KAnnual Savings
1000+IoT Sensors
25%Energy Saved
- Unplanned downtime reduced from 15% to 3%
- Maintenance costs reduced by 40%
- Production efficiency improved by 18%
- Defect rate reduced by 35%
- ROI achieved within 8 months
Client Testimonial
★★★★★
"The IoT platform has completely transformed our manufacturing operations. We can now predict equipment failures weeks in advance and schedule maintenance without disrupting production. The savings have been substantial."