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Factory Automation & IIoT Software

A factory floor generates terabytes of data every single day, yet most of it is ignored. True factory automation requires bridging the gap between Operational Technology (OT)—the physical machines, PLCs, and SCADA systems—and Information Technology (IT)—your cloud dashboards and ERPs. Vanavya Tech engineers custom Industrial Internet of Things (IIoT) software. We extract high-frequency data from your machinery and transform it into actionable, real-time intelligence, enabling true lights-out manufacturing and aggressive OEE (Overall Equipment Effectiveness) optimization.

Key Industry Problems

  • ⚠️ Complete blindness regarding micro-stops and actual machine cycle times.
  • ⚠️ Inability to extract data from legacy or proprietary PLCs (Siemens, Allen-Bradley).
  • ⚠️ Overwhelming "data swamps" where too much data is collected but never analyzed.
  • ⚠️ High latency when sending critical safety or control commands to the cloud and back.

How We Solve These Challenges

Problem: Protocol Translation (IT/OT Convergence)

Solution: We develop custom edge gateways that translate proprietary industrial protocols (Modbus, OPC UA) into lightweight, web-friendly protocols (MQTT, AMQP), allowing real-time streaming to the cloud.

Problem: Cloud Latency for Critical Operations

Solution: We utilize Edge Computing. Instead of sending raw vibration data to the cloud for analysis, we deploy lightweight Machine Learning models directly onto industrial PCs on the factory floor, ensuring millisecond reaction times to prevent machine damage.

Digital Transformation Strategy

The ultimate goal of IIoT is the creation of a "Digital Twin"—a real-time, virtual replica of your physical factory floor. By visualizing live telemetry data overlaid on a 3D model of your plant, operations managers can instantly identify bottlenecks, track AGVs (Automated Guided Vehicles), and simulate production changes before touching a single physical machine.

Generative AI Use Cases

  • 🤖 Vibration and acoustic AI analysis for ultra-precise Predictive Maintenance.
  • 🤖 AI-driven energy optimization, automatically adjusting HVAC and machine power states during non-peak hours.
  • 🤖 Computer Vision for robotic arm guidance and automated QA inspection.

Workflow Automation

We automate OEE (Overall Equipment Effectiveness) calculation. Instead of operators manually writing down scrap counts and downtimes, our software automatically logs machine states, calculating exact Availability, Performance, and Quality metrics in real-time on a massive screen overlooking the factory floor.

Success Stories

Steel Rolling Mill

Result: Deployed custom IIoT software reading telemetry from 200+ motors via OPC UA. AI predictive maintenance eliminated two catastrophic motor failures in the first year, saving $1.2M.

Frequently Asked Questions

Can you connect to our 20-year-old CNC machines?

Yes. Even if a machine lacks modern ethernet ports, we work with hardware partners to retrofit legacy machines with external sensors (accelerometers, current clamps) and use custom edge software to digitize their outputs without altering the machine's original PLC.

How much data will this generate, and won't cloud storage get expensive?

Sensors generate massive data, but you don't need to store all of it forever. We implement data down-sampling strategies. We keep high-resolution data for the last 7 days for immediate analysis, and roll it up into hourly averages for long-term, cheap cold storage (like AWS S3 Glacier).