Industrial IoT
Industrial IoT solutions for manufacturers
Industrial IoT connects machines, sensors and material to software so a plant can see and act on what is happening without walking the floor. For most manufacturers the useful first projects are machine monitoring, energy and utility metering, condition monitoring of critical assets and material tracking, built on one data layer that later carries MES and analytics.
Free scoping call. We start with one line, never change your machine logic, and you own the code and the data.
- material movements tracked a day, integrated steel plant
- 720,000+
- fewer dispatch errors with RFID and barcode dispatch
- 90%
- items an hour through RFID warehouse automation
- 16,800
Company reported project figures, not independently audited, not a promise for another plant. Samsung Business Insights: our RFID warehouse automation story (opens in a new tab). Forbes India Brand Connect (sponsored): founder profile (opens in a new tab).
Sound familiar?
- An IIoT pilot produced nice dashboards and nobody changed anything because of them.
- Sensors were bought before anyone agreed what question they should answer.
- Each department runs its own small data project with its own tags and names.
- Energy, air and utility costs are known per month, never per line or shift.
Each of these is output, margin or time you have already paid for and are not getting back.
What you get
A loss first plan
The one loss or risk to reduce, the owner who acts on it, and the data needed.
The backbone
Edge gateways, broker and a unified naming structure you own.
One working application
OEE, downtime, energy or condition monitoring, live on one area.
A pattern to scale
The same gateway, naming and security pattern for every new area.
What we have built
In an integrated steel plant in India, our material tracking covers warehouses, central stores and vendor yards: more than 720,000 material movements tracked per day, and a 90 percent reduction in dispatch errors after RFID and barcode based dispatch.
Figures are company reported from past projects. They are not independently audited benchmarks and are not a promise for another plant. Read the case studies.
How we work
What we do
We design and implement IIoT from machine to application: survey, sensors and gateways, broker and unified namespace, and the application that uses the data, often OEE, downtime or maintenance first. Our engineering team is in Belagavi and Bengaluru, India, and works with plants across India and with US manufacturers on Eastern business hours.
How we start
- 1Loss first. Name the loss or risk to reduce and who will act on the data.
- 2Survey. Machines, signals, network and security constraints.
- 3Pilot. One line or asset group, with the application and the owner in place.
- 4Scale on standards. Same gateway pattern, broker and naming for every new area.
How it works
Platform or build
Commercial IIoT platforms offer ready connectors, storage and dashboards and suit teams that want to configure rather than build. The trade offs are licence cost that grows with devices and tags, and data models tied to the platform. A lean stack of open standards (OPC UA, MQTT, a time series database and your own naming structure) keeps you portable. We work with either; the important decision is who owns the naming and the data.
Why IIoT pilots stall
- A pilot with nice dashboards and no owner who changes anything because of them.
- Every project connecting to machines separately, with different tag names.
- Sensors chosen before the question is clear.
- No plan for the OT network and security, so IT blocks the rollout.
Background
What an IIoT solution is made of
| Layer | What it does | Examples |
|---|---|---|
| Devices | Produce data | PLCs, CNCs, meters, vibration and temperature sensors, RFID readers |
| Edge | Collect, filter, buffer, secure | Industrial gateways, edge PCs |
| Transport | Move data to consumers | MQTT broker, OPC UA |
| Context | Name and model the data | Unified namespace, asset hierarchy |
| Applications | Turn data into action | OEE, energy, maintenance, MES, dashboards, AI |
IIoT use cases that pay back first
- Machine monitoring for output, downtime and OEE on mixed and legacy machines.
- Energy and utility metering by line and shift, including compressed air and power factor.
- Condition monitoring of critical assets such as compressors, blowers, gearboxes and pumps.
- Material and container tracking with RFID or BLE between stores, lines and dispatch.
- Process parameter logging for quality and customer audits.
When we are not the right choice
- You want a large platform licence before a single use case is proven.
- There is no one in the plant who will own the data and act on it.
Common concerns, answered
Will this disrupt production?
No. We connect read only first, install during planned stops, and edge devices buffer data so a network problem never stops a machine. Nothing writes to a PLC without your controls team and a test.
Our machines are old. Do we need to replace them?
No. Old machines are the usual case. A running signal, a cycle signal or a current sensor on the motor is enough to start, without touching the machine program.
We tried a system before and nobody used it.
That is the most common failure, so we design with the operators and supervisors who will use it, start with one report they already fill in by hand, and only extend once they rely on it.
What about IT security?
Read only by default, a segmented OT network, and a review with your IT team before anything connects, following the ISA/IEC 62443 zone approach.
We will not replace SAP or Oracle. Do we have to?
No. We connect to the ERP you already run through its standard interfaces and add what the shop floor is missing. Your ERP stays the system of record.
Do your engineers understand a heavy industrial floor?
Our systems run in steel plants, warehouses and process lines. We start every project by walking the line with your operators and supervisors, and the first release is tested by them, not only by IT.
Are we locked in?
No. You own the source code and the data, documented, in your own repository. Another team can maintain it.
Frequently asked questions
What is the difference between IoT and IIoT?
Industrial IoT applies connected devices to industrial assets and processes, where reliability, safety, legacy equipment and control systems matter. Consumer IoT has different priorities.
Do we need to replace old machines for IIoT?
No. Retrofit sensors and edge I/O can monitor state, counts, energy and condition on old machines without changing their controls.
Should IIoT data be on premise or in the cloud?
Either works. Many plants keep collection and critical applications on premise, and send summarized data to the cloud for group reporting. The choice depends on connectivity, security policy and cost.
How is IIoT related to MES?
IIoT provides machine and sensor data. An MES uses that data to direct and record production against orders. A well designed IIoT layer becomes the data source for the MES.
How much does an IIoT project cost?
It depends on the number of machines, the connection method for each and the applications. A pilot on one line is a small fraction of a plant wide rollout and is the right way to size the rest.
Related reading
References
Start with one line and one number
We scope one line, agree the number that should move, and show it moving before anything is scaled. You keep the code and the data.
Step 1
An engineer reads it
Not a sales bot. Our team replies within 24 hours with questions or times for a call.
Step 2
30 minute call
Your process, machines, systems and the number you want to move. We tell you honestly if we are a fit.
Step 3
A written scope for one line
What we would connect, what you would see, how long it takes. You decide; nothing starts without your approval.
Reviewed by Amey Kadle, Founder, Ajinkya Technologies. Last reviewed: .