CASE STUDY / Manufacturing / 2026
Smart Factory IoT
An Industry 4.0 smart factory deployment — IoT sensors, predictive maintenance AI, digital twin modelling and real-time production analytics.
-65%
Downtime
3.2x
ROI
2026
Delivered
3+
Technologies
01 / The Challenge
Unplanned machine downtime was costing the plant crores annually. Maintenance was purely reactive — machines were serviced on fixed schedules or after failure, never when actually needed.
02 / The Solution
- Sensor mesh across 120+ machines streaming vibration, temperature and load telemetry to Azure IoT Hub
- Predictive maintenance models that flag failure signatures 7–10 days in advance
- Digital twin of the production floor for scenario planning and bottleneck analysis
- Real-time OEE dashboards on the shop floor and in the boardroom
03 / The Results
Unplanned downtime reduced by 65%
3.2x return on investment within 18 months
Maintenance cost per machine-hour down 38%
IoTPythonAzure IoT Hub