Case Study

IoT Sensors and Data Monitoring

Project Background:

This Automotive T1 supplier has significant global manufacturing capabilities. To grow the business in the US, the client invested significant capital to increase production capacity.
To ensure capacity increase is achieved, unplanned machine downtime must be reduced.
The client wanted to introduce technology and data monitoring to better plan to maintenance and to reduce the operating costs.

Reduction of unplanned downtime due to motor failure
Reduction of production costs and operating expenses by eliminating failed steam traps
Reduction of carbon emissions due to energy usage in the steam system
Optimize maintenance staff resource utilization in both mixing and curing
Keep the manufacturing environment safe for employees with no accidents

Introduce battery-less IoT sensors powered by thermal electric generator and photovoltaic cell
Install a total of 150 sensors in the manufacturing plant to monitor steam traps and mixing motors
Monitor the live asset data to:
- Identify any anomalies in steam trap temperatures to alert of energy loss
- Identify any anomalies in motor vibration to alert for early-intervention maintenance
Monitor data collected and generate notification reports, a one-slide executive summary of the potential failure to be distributed to plant personnel
Support and troubleshoot any machine items, collecting failure data for predictive/prescriptive system training

Visualized results though web-based dashboard for cost savings and carbon accounting
10k+ anomalies detected and prioritized, leading to over $60k realized savings within 2 years (20% ROI achieved)
20+ predicted early machine failures, confirmed by the client. Prioritized and planned maintenance to prevent line stoppage and plant downtime.
300+ MT CO₂ Avoided