Development of an IoT Platform for Process Automation, Monitoring, and Compliance Management

The client faces difficulties in real-time monitoring of hazardous work environments, equipment performance, and building systems across geographically distributed plants. Ensuring compliance with safety and environmental regulations, maintaining optimal machine utilization, and reducing downtime present significant operational challenges. Existing manual processes lack agility and comprehensive visibility, risking safety incidents, regulatory penalties, and inefficient resource allocation.

A mid-to-large manufacturing enterprise seeking to enhance operational efficiency, ensure safety compliance, and monitor equipment health across multiple production facilities.

• Develop an scalable IoT platform capable of integrating diverse sensors and devices for comprehensive data collection across facilities.
• Enable real-time monitoring of environmental conditions, equipment health, and building system parameters to ensure safety and operational efficiency.
• Implement automated alerts, alarms, and remote command capabilities to promptly address safety violations and equipment issues.
• Create a unified, visual dashboard providing geographic and parameter-specific insights for facility managers and safety personnel.
• Support customizable reporting for regulatory compliance, maintenance planning, and operational analysis, with reporting options ranging from monthly to custom durations.
• Achieve high system reliability, scalability, and security to support future expansion and data integrity.

• Device provisioning and management for WiFi, LTE, and sensor peripherals
• Real-time data acquisition from environmental sensors (air quality, water quality, contaminants)
• Equipment health monitoring including temperature and system diagnostics
• Building system monitoring such as HVAC, elevators, fire safety systems
• Automated alerts and alarms triggered by threshold breaches or anomalous conditions
• Remote command execution for connected devices to initiate repairs or safety procedures
• Visual low-code workflow interface for mapping triggers, workflows, and automations
• Unified, georeferenced reporting dashboard with graphical overlays for multi-site operations
• Customizable reporting capabilities for compliance, maintenance, and operational metrics

• Sensor devices and peripherals for environmental and equipment data acquisition
• Alert and notification systems for proactive safety management
• Reporting tools for regulatory compliance and operational insights

• System scalability to support additional sensors and facilities with minimal latency
• Reliable real-time data processing with latency under 2 seconds
• Robust security measures to protect sensitive operational data and device access
• High availability architecture ensuring 99.9% uptime
• Compliance with data privacy and security standards applicable to industrial IoT systems

The implementation of this IoT platform aims to improve safety compliance and operational efficiency by providing real-time insights, predictive maintenance capabilities, and automated workflows. Expected outcomes include a reduction in safety incidents, improved machine utilization rates, and streamlined regulatory reporting, ultimately driving cost savings and enhanced regulatory adherence across multiple manufacturing sites.