How a Smart Factory Used Predictive Maintenance & PLC Monitoring to Slash Downtime

Smart Factory Transformation: PLC-Based Cloud Monitoring for Indian Textile Manufacturing

Client
:
A leading garment manufacturing company based in India
Objective
:
Transform traditional operations into a smart factory with real-time PLC monitoring and predictive maintenance
Delivered by Nuventure
:
Complete legacy device integration solution with IoT app development and AI-powered predictive analytics

The Challenge

Textile machines with legacy PLCs had frequent unexpected breakdowns

No real-time visibility into critical PLC parameters across production lines

Manual monitoring limited to twice per shift inspections

Reactive maintenance approach causing expensive emergency repairs

Improper production planning due to lack of real-time machine performance data

Our Solution

Direct PLC integration with existing legacy devices without production disruption

Secure MQTT and OPC-UA protocols for cloud data/internal server transmission

Custom IoT app development for real-time monitoring dashboards, for industrial engineers to monitor the activities and make strategic decisions

AI service provider capabilities for predictive maintenance algorithms tailored to specific devices and environments for accurate results

AI-IoT Integration Highlights

Real-Time PLC Monitoring with AI-Powered Predictive Maintenance for Complete Operational Excellence

Operators receive instant smart mobile alerts including SMS, call, and WhatsApp, when critical parameters provided in PLC exceed thresholds or show unusual patterns

AI algorithms predict machine failures 3-5 days in advance using data being trained from PLC

Real-time smart factory dashboards show all production line status for VP and CXO, to understand the gaps and make strategic decisions.

AI suggestions based on data which includes employee performance, production line efficiency gaps, work category analysis and worker planning.

Automated maintenance scheduling based on actual equipment condition using internal tools integration to send automated mails to 3rd party vendors to schedule the maintenance and follow-up.