IoT & Controllers

Facility teams operated with effectively zero real-time visibility into floor conditions — ambient temperature, machine run/idle/fault state, throughput per line, energy draw. Visibility was limited to manual walkthroughs on a fixed schedule or end-of-shift/next-morning reports compiled by hand. This meant equipment degradation, environmental excursions (e.g. a cold-chain breach), and line stoppages were routinely discovered hours after they began, well past the window where early intervention would have prevented downstream cost — spoiled product, unplanned downtime, or safety risk.

We began with a full site survey to map every point requiring monitoring — machine I/O, ambient conditions, access points, utility meters — and cross-referenced this against existing controller infrastructure to identify what could be integrated versus what needed new hardware. Sensors and controllers were deployed at each point and wired (or connected wirelessly via LoRaWAN/Wi-Fi, depending on site density and RF conditions) into an edge gateway. The gateway performs local buffering and store-and-forward so telemetry isn't lost during network drops or WAN outages, applies basic signal validation and normalization before transmission, and pushes data upstream to a live dashboard. Threshold- and rate-of-change-based alerting was configured per point in collaboration with the facility team, so alerts reflect operational reality rather than generic defaults, and every reading is retained for historical trend analysis and compliance reporting.

Facility managers moved from next-day discovery to sub-minute awareness of floor conditions. Mean time to detect equipment anomalies dropped from hours to minutes, giving maintenance teams a genuine window to intervene before a fault escalated into unplanned downtime. The historical data layer also gave the client a baseline for predictive maintenance planning and energy optimization work that wasn't previously possible without a live data source.