IoT Data Platform for Smart Manufacturing
Built real-time IoT data platform processing 10M+ sensor readings per hour, enabling predictive maintenance and reducing equipment downtime by 45%.
Industry
Manufacturing
Service
Data Engineering & Infrastructure
Timeline
8 months
Team Size
10 engineers (IoT specialists, data engineers, ML engineers)
The Challenge
A global manufacturer with 25 production facilities worldwide struggled with unplanned equipment downtime costing $2M monthly. Legacy systems couldn't handle real-time IoT data from 50,000+ sensors, and maintenance was entirely reactive.
Key Pain Points:
- Unplanned downtime averaging 12% of production time
- Unable to process real-time sensor data at scale
- Reactive maintenance leading to costly emergency repairs
- No visibility into equipment health across facilities
- Data silos preventing cross-facility analysis
- $24M annual cost from equipment failures
Our Solution
We built a cloud-native IoT data platform with real-time analytics and predictive maintenance capabilities.
Our Approach
- 1Designed scalable data architecture on Azure IoT Hub
- 2Implemented real-time streaming pipelines using Azure Stream Analytics
- 3Built data lake for historical analysis using Azure Data Lake Storage
- 4Developed predictive maintenance models using Azure ML
- 5Created real-time dashboards for equipment monitoring
- 6Implemented automated alerting for anomaly detection
- 7Established data governance for multi-facility data sharing
- 8Trained maintenance teams on new predictive maintenance workflows
Technologies Used
Azure IoT HubAzure Stream AnalyticsAzure Data Lake StorageAzure Machine LearningApache KafkaTimescaleDBGrafanaPythonMQTT Protocol
The Results
The platform now processes 10M+ sensor readings hourly and has transformed maintenance operations.
TOTAL ROI
$18.5M
in annually
Downtime Reduction
45%
Decrease in unplanned equipment downtime
Maintenance Costs
32%
Reduction in emergency maintenance costs
Equipment Lifespan
25%
Increase in average equipment lifespan
Production Efficiency
18%
Improvement in overall production efficiency
"This platform transformed us from reactive firefighting to proactive maintenance. We now predict failures weeks in advance and schedule maintenance during planned downtime."
VP of Manufacturing Operations
Industrial Manufacturing Corporation
Ready for Similar Results?
Let's discuss how we can help you achieve transformational outcomes with your data.