Transforming Factory Data into Actionable Intelligence
At DEIENAMI, we engineered and deployed a robust Industrial Machine Logger system, designed to digitize and optimize shop-floor operations for a manufacturing organization embracing Industry 4.0 transformation. The goal was to develop a reliable, real-time data collection system from both modern and legacy equipment, enabling deeper visibility into machine performance and maintenance needs.
The Challenge
Manufacturing units often face challenges such as:
- Lack of visibility into machine utilization and efficiency
- Manual logging of machine metrics, leading to delays and inaccuracies
- Difficulty in predicting machine failures or performance drops
- Inefficient integration between machines and ERP/MES systems
The client needed a scalable, sensor-driven logging system that could plug into various machines and collect live data to drive preventive maintenance, production planning, and overall equipment effectiveness (OEE) tracking.
Our Solution
We developed a smart Industrial Machine Logger using modern IoT and IIoT technologies that enables real-time monitoring, analysis, and alerting based on live machine data.
Key Features:
- Sensor & Edge Integration
Connected with machines via microcontrollers and Raspberry Pi to capture:- Runtime & idle time
- Fault codes & alerts
- Vibration levels & temperature
- Cycle counts & energy usage
- Offline Caching & Real-Time Sync
Supports data buffering during network loss and syncs automatically once reconnected. - Intelligent Dashboards & Reports
Plant managers can view:- Multi-machine operational status
- Downtime trends
- Performance KPIs
- Anomaly alerts
- Custom Alerts & Threshold Triggers
Enables predictive maintenance by alerting when:- Temperature exceeds safe limits
- Vibration signals indicate wear/tear
- Machines stay idle beyond tolerance
- ERP, MES, and CMMS Integration
Seamless data exchange with online ERP and maintenance systems for a unified view of operations.
Tech Stack
| Component | Technology Used |
|---|---|
| Backend API | Golang (Gorilla Mux) |
| Frontend Dashboard | React.js |
| Database | PostgreSQL + MongoDB |
| Edge Devices | Raspberry Pi, NodeMCU |
| Protocols | MQTT, HTTPS |
| Hosting & Deployment | Client-hosted on-premise |
| Integration Points | ERP & MES via REST APIs |
Impact & Benefits
- ⏱ Reduced unplanned downtime through early fault detection
- 📈 Improved machine utilization rates via real-time insights
- 🔧 Better preventive maintenance planning based on data trends
- 💰 Cost savings from fewer breakdowns and production delays
- 🧠 Informed decision-making with continuous access to accurate operational data
DEIENAMI’s Role
We handled end-to-end product engineering, including:
- Requirements discovery and tech architecture design
- IoT firmware development and protocol design
- API development and dashboard creation
- Database modeling and secure data pipelines
- Deployment in on-premise infrastructure
- User training, handover documentation, and post-deployment support
Our choice of Golang ensured high performance for concurrent data ingestion, while React powered a dynamic, real-time visualization interface. Using both PostgreSQL and MongoDB allowed structured and unstructured machine data to coexist in a scalable manner.
Who This Is For
- Smart Factories & OEMs
- Process Manufacturers
- Maintenance Managers
- Industrial IoT Integrators
- Factories upgrading toward Industry 4.0
Ready to Turn Your Machines into Intelligent Assets?
Whether you’re starting your digital factory journey or upgrading existing systems, DEIENAMI helps you design and deploy customized IoT systems that unlock real-time insights and performance optimization.
