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Solving Real Manufacturing Problems with
Smart Technology
Unplanned Downtime
Problem: Frequent, unpredictable machine stoppages lead to production losses, missed deadlines, and high maintenance costs.
Our Solution:
• Real-time Downtime Monitoring with root cause categorization.
• Downtime Pareto Analysis with integrated maintenance codes.
• MTBF & MTTR tracking for reliability insights.
✅ Result: Reduced unplanned downtime and optimized maintenance schedules.
Low Machine Efficiency & Poor OEE
Problem: Plants struggle with low utilization rates and can't pinpoint whether performance issues stem from availability, performance, or quality.
Our Solution:
• Real-time OEE Monitoring with drill-downs.
• Cycle Time Variance Analysis to detect bottlenecks.
• Workforce Efficiency Tracking to improve human performance.
✅ Result: Better resource utilization and higher throughput.
Poor Quality & High Rejection Rates
Problem: Quality issues lead to customer dissatisfaction, rework, and scrap generation.
Our Solution:
• Rejection & Rework Analysis by product, machine, and shift.
• PPM (Parts Per Million) Reporting and cost of quality.
• QA-QC Integration for in-line and final inspection tracking.
✅ Result: Reduced quality failures and increased customer trust.
Manual Tracking of Production & Downtime
Problem: Relying on logbooks and Excel leads to inaccuracies and delayed decisions.
Our Solution:
• Automated Production Counters with good/bad part tracking.
• Interactive Dashboards for real-time visualization.
• Production History Reports for audit, analysis, and compliance.
✅ Result: Digitized shop floor with real-time control.
Lack of Process Traceability
Problem: No visibility into how raw materials, machines, and human inputs impact the final output.
Our Solution:
• End-to-End Traceability from raw materials to delivery.
• Sensor Integration (temperature, pressure, tonnage, etc.) for granular control.
• Audit Trails for all quality and production events.
✅ Result: Full process transparency for audits and root cause analysis.
High Energy Costs
Problem: Machines consuming excess energy go unnoticed, leading to high operational costs.
Our Solution:
• Energy Monitoring Dashboards per machine/shift/product.
• Carbon Footprint Tracking for environmental compliance.
• Anomaly Alerts for spikes in usage.
✅ Result: Reduced energy bills and improved sustainability.
Imbalanced Workloads & Idle Time
Problem: Some operators and machines are overloaded while others stay idle.
Our Solution:
• Dynamic Workload Balancing based on real-time data.
• Line Balancing Metrics to improve flow.
• Operator Efficiency Reports to manage teams better.
✅ Result: Streamlined operations and reduced inefficiencies.
Integration with Existing Systems
Problem: Difficulty in connecting machines, ERP, and legacy systems.
Our Solution:
• ERP & SAP Compatibility (push & pull APIs).
• Universal PLC Support for easy integration.
• Modular Architecture for scalable, custom deployments.
✅ Result: Seamless digital transformation without infrastructure overhaul.
Ready to Solve Your Industry Challenges?
IIoT Technologies is built to eliminate guesswork, reduce waste, and unlock operational excellence. Whether you're a small unit or a multi-plant enterprise, we tailor solutions to your needs.
Book a free consultation 👉