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Integrated IoT Predictive Maintenance and Self-Service BI Platform for Manufacturing Optimization

itmagination.com

Manufacturing

Consumer products & services

Business Intelligence and IoT Integration Challenges

Need for continuous, modernized reporting during ERP rollout across 10 countries, combined with optimizing production line maintenance costs, minimizing downtime, and reducing product warranty claims through predictive analytics.

About the Client

A leading Nordic paint company specializing in premium surface products, operating in 11 countries with 2,400 employees and €582M annual revenue. Part of PPG since 2021, with a focus on innovation and digital transformation.

Digital Transformation Goals

Implement self-service BI capabilities with mobile dashboards for real-time KPI analysis
Reduce production downtime by 20% through predictive maintenance models
Centralize global and local business analytics tools
Integrate IoT sensor data with ERP and BI systems for proactive quality control

System Capabilities

Power BI-based self-service dashboard creation
Predictive maintenance models using sensor data (temperature, vibration, etc.)
Mobile reporting with offline access
Centralized data model integrating sales, finance, manufacturing, and IoT data
Automated alerts for maintenance scheduling and quality deviations

Technology Stack

Microsoft Azure cloud platform

Power BI for visualization

Machine learning algorithms (neural networks, decision trees)

In-memory data modeling

IoT sensor integration frameworks

System Integrations

Microsoft Dynamics AX ERP
Production line IoT sensors
Existing BI analytics systems
Mobile device management platforms

Operational Requirements

Scalable cloud architecture for 10+ countries
Real-time data processing (<1 second latency)
Enterprise-grade security with GDPR compliance
99.9% system uptime SLA
Cross-device responsive design

Expected Business Outcomes

Enables 30% faster maintenance response times, 15% reduction in warranty claims, and centralized analytics for 2,400 employees. Supports proactive manufacturing parameter adjustments and data-driven decision-making across 11 markets.