Industrial IoT Machine Telemetry & OEE Monitoring
Real-time PLC data ingestion, machine performance analytics, and automated downtime alerting.
A precision manufacturing plant operated multiple machining lines without centralized telemetry. Plant supervisors relied on end-of-shift paper logs to tally scrap counts, machine cycle times, and operator downtime reasons.
Lack of real-time machine visibility meant micro-stoppages went unnoticed, scrap defects compounded before detection, and calculating Overall Equipment Effectiveness (OEE) was a slow, retrospective exercise.
Our Architectural Approach
FlipWorks developed an industrial IoT telemetry architecture, tapping machine PLCs via standard protocols and deploying edge data collectors that stream high-frequency metrics into a centralized time-series dashboard.
The Deployed Software Platform
We delivered a plant-wide Smart Factory Platform featuring live touchscreen operator terminals at each machine, real-time OEE analytics for supervisors, and automated alerts for temperature and vibration anomalies.
System Topology & Architecture
Hardware-to-Cloud Asset Tracking Pipeline
Passive UHF EPC Gen2 tags read by fixed portal readers and handheld scanners.
Key Architectural Highlights
Edge gateway data collector communicating over OPC-UA and Modbus TCP protocols
High-throughput MQTT broker ingesting continuous telemetry with local buffering during network interruptions
TimescaleDB time-series database optimized for millisecond-level telemetry aggregation
Live Andon visual alert boards displayed on overhead factory floor monitors
Capabilities Delivered to Client
- →Provided plant managers with real-time, objective visibility into factory line availability
- →Accelerated maintenance response times to machine stoppages via automated paging
- →Replaced manual paper tally sheets with accurate digital production records
Technologies Utilized
Other Case Studies
Facing similar operational bottlenecks?
Consult with our engineering leads to design the optimal architecture for your enterprise.
Schedule Architecture Consultation