Industrial Power & Asset Monitoring Platform
47 machines. Zero visibility. We fixed that.
End-to-end IoT monitoring system — from custom ESP32 firmware on the factory floor to a real-time web dashboard with OTA update capability across the entire device fleet.
The Challenge
A manufacturing facility operating 47 production machines had zero automated visibility into equipment status, power consumption, or failure indicators. Maintenance was entirely reactive — machines were discovered to have failed only when production stopped. The cost of unplanned downtime ran into hundreds of thousands of rands annually, yet no off-the-shelf solution could interface with the legacy machine controllers already on the floor.
The Solution
We designed the entire stack from the hardware layer up. Custom ESP32-based sensor units were engineered for each machine class, measuring power draw, operating temperature, vibration signatures, and runtime hours. Each unit runs proprietary C++ firmware with AES-encrypted MQTT communication and full OTA update capability — firmware changes deploy across the entire 47-unit fleet without a single physical visit to the floor.
A .NET Core API ingests telemetry streams in real time, evaluates configurable alerting rules per machine, and feeds a Next.js dashboard accessible from any device on the facility network. Facility managers have live machine status, 18 months of historical trend data, and push alerts the moment any machine crosses a defined threshold.
Results
- 47 machines monitored continuously in real time
- OTA firmware updates deployed fleet-wide in under 90 seconds
- Alert response time reduced from hours to under 3 minutes
- 18-month historical trend data with anomaly detection
- Zero physical access required for firmware changes post-deployment
- Maintenance scheduling shifted from reactive to predictive
More Work
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