Industrial IoT (IIoT) Factory Dashboard

An automotive parts manufacturer operating 30 high-speed CNC (Computer Numerical Control) machines had zero visibility into their factory floor performance.

Management only found out a machine was broken when the daily production quota was missed. Their maintenance strategy was entirely reactive—waiting for a spindle to shatter before replacing it, which caused 2-3 days of catastrophic downtime per incident. They were manually calculating OEE (Overall Equipment Effectiveness) using paper logs at the end of every shift, a process fraught with human error and "pencil-whipping" by operators trying to hide micro-stops.

Vanavya Tech designed a fully automated Industrial IoT (IIoT) ecosystem that transformed their analog factory into a "Smart Factory."

We did not replace their expensive CNC machines. Instead, we retrofitted them with edge IoT gateways that tap directly into the PLCs (Programmable Logic Controllers) via the OPC-UA protocol. This allowed us to extract live telemetry data—spindle RPM, motor temperature, vibration, and exact fault codes—in real-time.

This data is streamed into a custom Vue.js Dashboard displayed on massive 65-inch monitors on the factory floor. Plant managers now have a live, color-coded grid of all 30 machines. More importantly, we applied Machine Learning to the historical vibration data. The system now alerts maintenance teams to replace a spindle bearing *days before* it actually shatters, shifting the factory from reactive to predictive maintenance.