User Research | Business Case | UX/UI
Transforming manufacturing productivity with smart IoT and predictive analytics
Smart Manufacturing
Industrial IoT
Challenge
Small and medium size manufacturing and production businesses in majority of the cases struggle with low machine availability, inefficient processes, and a lack of real-time insights. Many rely on outdated machinery and manual reporting, leading to unplanned downtime, slow issue resolution, and supply chain bottlenecks.
With machine availability dropping as low as 35%, productivity suffers, impacting profitability and competitiveness. To stay ahead, manufacturers need an AI-powered IoT solution that enables real-time monitoring, predictive maintenance, and automated decision-making to optimize operations and drive efficiency.
How did we engage?
We collaborated with a leading technology provider to define and develop an IoT-powered smart manufacturing solution tailored to the needs of small and medium-sized manufacturers. Through a structured innovation process, we conducted workshops to frame the challenge, identify key pain points, and align business goals with customer needs.
Our engagement included persona development, journey mapping, and defining core solution features to ensure a seamless integration of IoT, predictive analytics, and AI-driven automation. By working closely with key stakeholders, we outlined a scalable and efficient implementation roadmap, focusing on real-time monitoring, proactive maintenance.
Solution
The new IoT-driven manufacturing solution leverages sensors and AI to monitor industrial machinery, predict failures, and automate maintenance and inventory management. The key functionalities include:
- Real-time Machine Monitoring: IoT sensors track performance metrics and detect faults in machinery, reducing unexpected downtime.
- Predictive Maintenance: AI-driven insights predict when parts will fail, allowing proactive repairs and reducing maintenance delays.
- Automated Inventory Management: Integrated supply chain data ensures raw materials and spare parts are ordered before shortages occur.
- AI-Powered Shift Assistance: A natural language chatbot provides instant reports, troubleshooting, and recommended actions.
- Actionable Insights: A centralized dashboard visualizes machine performance, job completion rates, and overall equipment effectiveness (OEE).
Through seamless cloud integration and user-friendly dashboards, the solution enhances operational efficiency, helping manufacturers boost productivity while minimizing machine downtime.
Impact
The solution streamlined manufacturing operations, reducing downtime, enhancing productivity, and optimizing resource management through real-time monitoring, predictive analytics, and automation, leading to increased efficiency, profitability, and overall business growth.
Machine availability
Improved uptime through real-time monitoring and predictive maintenance.
Productivity
More jobs completed on time, reducing idle periods.
Profitability
Reduced downtime and optimized resource allocation improve margins.
