Development of a Modular IoT Platform for Manufacturing Process Automation and Optimization

The client’s existing manufacturing platform is outdated, limiting automation, customization, and real-time process optimization. This results in inefficiencies, increased error rates, and difficulties integrating new manufacturing needs or scaling operations seamlessly.

A large-scale manufacturing enterprise seeking to modernize its production facilities with an IoT-enabled, microservice-based industrial automation platform.

• Replace the legacy manufacturing platform with a flexible, scalable, microservice-oriented IoT system.
• Enable real-time data collection, business rule processing, and automated decision-making within manufacturing workflows.
• Reduce data request times and improve system responsiveness through optimized data handling strategies.
• Ensure secure, multitenant document and process management integrated into the platform.
• Streamline approval workflows and task timers for operational efficiency.
• Support dynamic material verification and inventory management to maintain production quality and consistency.
• Achieve high system reliability and performance under large data loads and concurrent operations.
• Deliver a customizable solution for varied client-specific factory needs to ensure fast deployment and tailored workflows.

• Business rules engine capable of evaluating live operational attributes and triggering automated actions.
• Secure document management system supporting version control, storage, retrieval, and multi-tenant access via REST APIs and messaging protocols.
• Work Instructions module providing step-by-step operational guides integrated into manufacturing workflows.
• Version approval workflow facilitating entity version verification, feedback collection, and authorized deployment.
• Timers management system managing scheduled tasks with callback capabilities for automation and process control.
• Material verification module configuring runtime material rules, triggering actions based on inventory status, and integrating with inventory systems.
• Master Data Management system supporting CSV import/export, API, Kafka, and direct database access for data synchronization across modules.

• Real-time messaging and event handling via Kafka and REST API
• Document storage and retrieval systems
• Inventory and material management systems
• Approval and workflow management tools
• External quality and process verification systems

• Scalability to handle large-scale data—minimizing data request times with micro UIs and optimized data flow
• High performance for real-time processing and event handling
• System reliability under high data throughput and concurrent operations
• Security measures including role-based access control and data encryption
• Ease of deployment and customization for different factory environments

The implementation of this advanced IoT manufacturing platform is expected to significantly improve operational efficiency by reducing data request response times, enhance process automation through real-time business rules, ensure secure document and workflow management, and support scalable customization for diverse manufacturing needs. Anticipated benefits include increased system reliability, streamlined approval and task management, and improved production quality, enabling the client to adapt rapidly to industry changes and scale operations effectively.