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Manufacturing
Industrial IoT Monitoring Platform
The Challenge
Three manufacturing facilities were experiencing unplanned downtime averaging 12 hours per month per facility. The root cause was a lack of real-time visibility into equipment health — maintenance was reactive rather than predictive.
The Solution
We built a real-time sensor monitoring platform consisting of:
- Edge devices running MQTT to collect sensor data from 12,000+ sensors
- A Flutter dashboard displaying real-time equipment health, alerts, and historical trends
- Predictive analytics using threshold-based alerting and trend analysis to catch issues before they cause downtime
The Results
- 34% reduction in unplanned downtime
- 99.9% platform uptime over 18 months
- 12,000+ sensors monitored across 3 facilities
- Under 2 second alert latency from sensor to dashboard
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