Industrial IoT Solutions for Connected, Predictive Operations
Connect machines, sensors and legacy equipment to a single IIoT platform for live OEE, predictive maintenance, energy visibility and safety monitoring. We handle sensors, edge gateways, PLC and SCADA integration, dashboards and ERP connectivity, with support across India.
What Are Industrial IoT Solutions?
Industrial IoT (IIoT) solutions connect machines, sensors, meters and controllers on the plant floor to software that monitors, analyses and automates operations. A typical IIoT architecture has four layers: sensing (vibration, temperature, current, pressure, flow, level and proximity sensors, plus data from PLCs and machine controllers); edge (industrial gateways that collect data over Modbus, OPC UA, Profinet, EtherNet/IP or MQTT and pre-process it locally); platform (cloud or on-premise software that stores time-series data, runs analytics and machine learning, and manages devices); and applications (OEE dashboards, predictive maintenance, energy management, quality and safety modules integrated with MES and ERP).
The business value comes from turning plant data into decisions. Real-time OEE shows availability, performance and quality losses per machine and shift. Predictive maintenance uses vibration, temperature and current signatures to flag bearing wear, misalignment or overload weeks before failure, reducing unplanned downtime and spare-part emergencies. Energy monitoring at machine and line level identifies idle consumption and peak demand. Environmental monitoring protects products and compliance in pharma, food and cold-chain operations. Because most Indian plants run a mix of new and decades-old equipment, retrofitting legacy machines with sensors and gateways is usually the first and highest-return step.
AIDC Solutions, the AIDC practice of Aeologic Technologies Pvt. Ltd., Noida, delivers IIoT projects end to end: sensor and gateway selection from OEMs such as Advantech, Teltonika and Siemens, PLC and SCADA integration, platform configuration, dashboards and analytics, and integration with SAP, Oracle, Microsoft Dynamics and MES systems. IIoT frequently combines with our RFID and RTLS solutions for material and WIP tracking, and with AI cameras for visual inspection and safety.
Live Machine and OEE Visibility
See availability, performance and quality per machine, line and shift in real time, with downtime reasons captured automatically.
Predictive Maintenance
Detect bearing wear, misalignment, overheating and overload from sensor signatures weeks before failure and plan maintenance in advance.
Energy and Compliance Control
Monitor energy at machine level and environmental conditions in critical areas to cut cost and meet quality and regulatory requirements.
How We Deliver an Industrial IoT Project
A phased approach that retrofits what you have, proves value on one line and scales across the plant.
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Plant Assessment
Inventory machines, controllers, protocols and existing SCADA or MES; define KPIs such as OEE, MTBF, energy per unit and compliance needs.
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Sensor and Gateway Design
Select sensors for legacy machines, tap PLC data via OPC UA or Modbus, and specify industrial gateways, networking and cybersecurity.
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Platform Setup
Deploy the IIoT platform (cloud or on-premise), model assets and lines, configure data pipelines, alarms and role-based dashboards.
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Analytics and Integration
Build OEE, predictive maintenance and energy models, and integrate with MES, SAP, Oracle, Dynamics and CMMS for work orders and reporting.
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Pilot, Scale and Support
Prove value on one line, train operators and maintenance teams, roll out plant-wide and provide monitoring and support.
Our Industrial IoT Solutions
IIoT applications delivered with sensors, gateways, platform, analytics and integration.
Machine Monitoring and OEE Solutions
Real-Time Availability, Performance and Quality
Connect new and legacy machines to capture run status, cycle counts, downtime reasons and quality data for live OEE.
- Automatic run, idle and down status capture
- Cycle count and throughput per machine
- Downtime reason capture with operator input
- OEE by machine, line, shift and SKU
- Andon alerts and escalation
- MES and ERP production confirmation
Predictive Maintenance Solutions
Condition Monitoring and Failure Prediction
Wireless vibration, temperature and current sensors with analytics that predict failures and generate CMMS work orders.
- Vibration, temperature and current sensors
- Bearing, misalignment and imbalance detection
- Threshold and ML-based anomaly alerts
- Remaining useful life estimates
- Automatic CMMS work order creation
- Maintenance KPI dashboards (MTBF, MTTR)
Industrial Automation and SCADA Integration
PLC, SCADA and MES Connectivity
Unify data from PLCs, SCADA and machine controllers over OPC UA, Modbus and MQTT into one platform without disrupting control systems.
- OPC UA, Modbus, Profinet and EtherNet/IP connectivity
- Edge gateways with local buffering
- Secure OT to IT data bridging
- Recipe and parameter monitoring
- Alarm management and reporting
- MES and digital twin integration
Energy Monitoring and Management
Machine-Level Energy Visibility
Smart meters and current sensors that attribute energy consumption to machines, lines and products.
- Smart meter and CT sensor integration
- Energy per machine, line and unit produced
- Idle and off-shift consumption detection
- Peak demand and power factor alerts
- Compressed air and utility monitoring
- Sustainability and ISO 50001 reporting
IoT Asset and Material Tracking
Connected Assets Across the Plant
Combine IIoT with RFID, BLE and RTLS to track tools, WIP, containers and material flow alongside machine data.
- RFID and BLE integration on the same platform
- Tool and container utilisation
- WIP location and ageing
- Material consumption vs production
- Returnable packaging visibility
- WMS and ERP synchronisation
Industrial Safety and Environmental Monitoring
Gas, Temperature, Humidity and Worker Safety
Sensors and alerts for hazardous gases, temperature excursions, humidity, dust and worker safety events in critical areas.
- Gas, smoke and dust sensors
- Cold room and clean room monitoring
- Pharma and food compliance logging
- Worker SOS and zone alerts
- Automated escalation and SMS or app alerts
- Audit-ready compliance reports
Industrial Protocols and Connectivity We Integrate
How the common plant-floor protocols and networks map to IIoT use cases.
| Protocol / Network | Layer | Typical Source | Use in IIoT | Notes |
|---|---|---|---|---|
| OPC UA | Application | Modern PLCs, SCADA, MES | Secure, structured machine data to platform | Preferred standard for new integrations |
| Modbus RTU / TCP | Application | Legacy PLCs, meters, drives | Energy meters, drives and older controllers | Widespread in Indian plants |
| Profinet / EtherNet/IP | Fieldbus | Siemens, Rockwell PLCs | High-speed machine data | Read via gateways without altering control logic |
| MQTT | Messaging | Gateways, sensors | Lightweight publish/subscribe to cloud or on-premise broker | Backbone of most IIoT platforms |
| LoRaWAN / BLE / Wi-Fi | Wireless | Battery sensors | Vibration, temperature, utility sensors on legacy machines | Retrofit without cabling |
| 4G / 5G | WAN | Gateways, remote sites | Remote plants, pumps and infrastructure | Private 5G for high-density plants |
We bridge OT and IT securely, with read-only access to control systems and segmented networks following IEC 62443 principles.
Industry-Specific Industrial IoT Applications
IIoT use cases we deliver most often in India.
Discrete Manufacturing
OEE, downtime analytics, predictive maintenance on presses, CNCs and conveyors, and tool life tracking in automotive, electronics and engineering plants.
Process and Pharma Plants
Environmental monitoring, batch parameter logging, utility monitoring and compliance reporting for pharma, chemicals and food.
Energy and Utilities
Smart metering, transformer and pump monitoring, remote asset health and distribution network analytics.
Warehousing and Logistics
Conveyor and sorter health, dock equipment monitoring, cold storage compliance and MHE telematics.
Oil, Gas and Mining
Remote equipment monitoring, gas detection, worker safety and predictive maintenance on critical rotating equipment.
Smart Buildings and Infrastructure
HVAC and chiller optimisation, energy management, water monitoring and facility asset health.
Benefits of Industrial IoT Solutions
Reduce unplanned downtime with predictive maintenance
Raise OEE with live loss visibility by machine and shift
Cut energy cost by attributing consumption to machines and products
Retrofit legacy equipment without replacing it
Automate production confirmations into MES and ERP
Protect product quality and compliance with environmental monitoring
Improve worker safety with gas, zone and SOS alerts
Build a data foundation for digital twins and AI
Related AIDC Solutions
IIoT platforms often ingest RFID, RTLS and vision data too. Explore the related technologies we integrate.
Frequently Asked Questions
Direct answers to common questions about Industrial IoT and smart factory projects
Industrial IoT (IIoT) solutions connect machines, sensors, meters and controllers to software that monitors, analyses and automates plant operations. They cover machine monitoring and OEE, predictive maintenance, energy management, environmental and safety monitoring, and integration with PLC, SCADA, MES and ERP systems.
Yes. Legacy machines are retrofitted with wireless vibration, temperature, current and proximity sensors, or with signal taps on indicator lamps and counters, connected through industrial gateways. This captures run status, cycle counts and health data without modifying the machine's control system.
OEE (Overall Equipment Effectiveness) multiplies availability, performance and quality to show how much of planned production time is truly productive. IIoT measures it automatically by capturing machine status and downtime, cycle counts against ideal cycle time, and good versus rejected parts, then presenting OEE by machine, line, shift and product.
Sensors continuously measure vibration, temperature and current on motors, pumps, gearboxes and bearings. Analytics compare these signatures against baselines and known failure patterns to detect wear, misalignment, imbalance or overload early, raise alerts and create maintenance work orders before the equipment fails.
Common plant protocols include OPC UA, Modbus RTU and TCP, Profinet and EtherNet/IP for PLC and controller data, MQTT for lightweight messaging to the platform, and wireless options such as LoRaWAN, BLE and Wi-Fi for battery sensors. Gateways translate between these so all data lands in one platform.
Yes. Production counts, downtime, quality and maintenance events can be posted to SAP, Oracle, Microsoft Dynamics, MES and CMMS systems through APIs or middleware, so production confirmations, work orders and inventory consumption happen automatically.
Yes, when designed properly. We follow IEC 62443 principles: read-only access to control systems, segmented OT and IT networks, encrypted MQTT or OPC UA communication, authenticated gateways, role-based access and regular patching. Data can stay on-premise where policy requires it.
Cloud platforms offer faster deployment, multi-plant visibility and scalable analytics. On-premise or hybrid deployments suit plants with strict data residency, limited connectivity or latency-sensitive control loops. Edge gateways buffer data locally in either model so nothing is lost during outages.
A single-line pilot covering machine monitoring and OEE typically takes 6 to 10 weeks, including sensor installation, gateway setup, platform configuration and dashboards. Predictive maintenance models mature over a few months of data, and plant-wide roll-outs are phased after the pilot.
Cost depends on the number of machines and sensors, gateway and network requirements, platform licensing (cloud subscription or on-premise), analytics scope and integration with MES or ERP. Retrofit pilots on a few critical machines are an economical starting point. Share your machine list and KPIs for a detailed estimate.
Ready to Connect Your Plant and Predict Failures?
Share your machine list, KPIs and systems. We will propose a retrofit-first IIoT architecture and quote a pilot line you can measure.
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