Smart Factory IoT Monitoring Platform

The Challenge

A mid-sized manufacturing company operating three production facilities needed real-time visibility into machine health, environmental conditions, and production throughput. Their existing monitoring relied on manual readings taken at shift changes, meaning equipment failures were only detected after they caused downtime — costing an average of four hours of lost production per incident.

Our Approach

Device layer: We selected industrial-grade temperature, vibration, and power-consumption sensors and developed firmware that publishes readings over MQTT at configurable intervals. Each device authenticates via X.509 certificates and supports over-the-air firmware updates.

Edge layer: On-site gateway devices aggregate sensor data, perform local anomaly detection to trigger immediate alerts without cloud dependency, and batch-forward data to the cloud during connectivity windows.

Cloud layer: AWS IoT Core ingests device telemetry, which flows through a processing pipeline built on AWS Lambda and Amazon Timestream for time-series storage. Threshold-based and ML-based alerting rules notify maintenance teams via push notification and email.

Application layer: A Flutter-based dashboard application — available on iOS, Android, and web — provides real-time and historical views of every sensor across all facilities. Operators can drill down from facility-level overviews to individual machine metrics, view trend graphs, and acknowledge alerts directly from the app.

Results

• 73% reduction in unplanned downtime within the first six months of deployment
• Real-time visibility across all three facilities from a single dashboard
• Predictive maintenance alerts enabled the team to schedule repairs during planned maintenance windows, reducing emergency interventions by over 60%
• The platform was designed for scale and has since been expanded to include two additional facilities with no architectural changes