INDUSTRY 4.0 · IIoT-NATIVE PLATFORM

Transform Your
Shop Floor Into a
Connected, Intelligent Factory

Real-time IIoT monitoring, predictive maintenance, AI-driven breakdown analysis, and digital shift handovers — all in one unified platform built for modern manufacturing operations.

40+
Machines Monitored
156
Live Sensors
<40ms
Data Latency
99.9%
Uptime SLA
OEE Today
82.4%
+4% vs yesterday
MTTR
2.3h
Target <2h
Production Floor — Live
LIVE · 4s REFRESH
ONLINE
28/40
CRITICAL
2
OPEN TKT
12
OEE
82%
UPTIME TREND — 7 DAYS
MC-007 · 98°C MC-012 · 8.2 mm/s MC-019 · Low Oil TK-0232 Resolved
8
Powerful Modules
25%
Avg OEE Improvement
40%
Reduction in MTTR
₹18L+
Monthly Cost Savings

Eight Integrated Modules.
One Unified Platform.

Every module is built ground-up for industrial operations — designed by QA leads and validated on real shop floors across discrete manufacturing, automotive, and aerospace sectors.

01

Production Command Dashboard

Role-based command center for Admin, Supervisor, Technician, and Operator. Real-time KPIs that adapt to who's logged in, with live alerts that demand action.

  • Live KPIs: Machines online, Critical alerts, Open tickets, OEE, MTBF, MTTR
  • Production-line efficiency strip with OEE component breakdown (A × P × Q)
  • Critical alert feed with one-click acknowledgement & technician dispatch
  • Shift activity timeline with AI-correlated event chains
  • Click-through navigation: every KPI takes you to its source module
See it in action
02

Machine Fleet & Live IIoT Monitoring

Every machine on your floor — connected, monitored, understood. Refreshes every 4 seconds via your IIoT gateway with full historical context per asset.

  • 40+ machines across multiple lines & bays with health scoring
  • Live sensors: Temperature, vibration, power draw, oil level, utilization
  • Machine deep-dive: gauges, profile, related tickets, breakdown timeline
  • AI predictive analysis: failure probability & remaining useful life
  • Compatible spare parts auto-linked per machine
See it in action
03

Breakdown Tracking & Resolution

From symptom to root cause — every breakdown captured, every fix documented. SLA-driven workflow with full audit trail and AI root-cause hints.

  • Dual scope tabs: Overall Breakdown & Today's Shift filtering
  • Kanban & List view toggle — same data, two perspectives
  • SLA timer on every ticket with visual urgency indicators
  • Full ticket CRUD: Raise → Assign → In Progress → Resolve (with mandatory RCA)
  • AI root cause analysis with similar-pattern history matching
  • Photo evidence upload with auto-geotagging
See it in action
04

Maintenance Management

Four-tab planner separating Today's plan, Preventive Maintenance, Patrol checks, and Weekly schedules. Bulk import via Excel saves hours on task assignment.

  • Four planning views: Today's Plan, PM Plan, Patrol Plan, Weekly Plan
  • Technician workload balancing with capacity % indicators
  • PM compliance tracking with overdue escalation
  • Bulk task import via Excel/CSV (assign hundreds at once)
  • Checklist file attachment (PDF / SOP / images) on every job
  • Maintenance cost analysis by type (PM, Breakdown, Patrol, Planned, Emergency)
See it in action
05

Spare Parts Inventory

ABC-classified inventory with AI-driven reorder analysis. Know which part will run out next — and place the PO before it does.

  • ABC classification (Critical / Important / Standard) with auto-categorization
  • Low-stock alerts with one-click PO generation to procurement
  • AI reorder analysis: depletion forecast vs lead time
  • Bulk parts import via Excel template (up to 5000 parts per file)
  • Per-part: supplier, lead time, machines used, consumption history
  • Multi-location stock tracking with QR scan support
See it in action
06

Safety Audits & Compliance

Build a real safety culture — not just paperwork. Gemba audits, NC tracking, near-miss reporting, and Identified vs Actual gap analysis. ISO 45001 ready.

  • Six audit types: 5S, Fire Safety, PPE, LOTO, Ergonomics, Gemba Walk
  • Identified vs Actual gap analysis (conversion rate & criticality)
  • NC tracking with photo evidence & CAPA closure workflow
  • Anonymous near-miss reporting (encourage reporting, no blame)
  • PPE compliance trend with weekly spot-check tracking
  • Real-time NC overdue dashboard for safety officers
See it in action
07

Digital Shift Handover

No more "I told the night shift verbally". Structured digital handover with AI-generated narrative, pending-job carryover, and dual sign-off accountability.

  • Two scope views: Overall Shift Data (monthly) & Last Shift Details
  • Production summary: Actual vs Planned, Variance, Achievement %
  • Active breakdowns & pending jobs auto-carried to next shift
  • AI-generated shift narrative from incident data & KPIs
  • Dual sign-off audit trail (outgoing + incoming supervisor)
  • Compliance tracking: submission rate, missed handovers, avg completion time
See it in action
08

Reports & Analytics

All your KPIs, charts, and trends in one place — with values visible directly on every chart (no hover required) and downloadable in PDF/Excel.

  • Today's OEE with full breakdown (Availability × Performance × Quality)
  • 7-day & 30-day OEE trend vs target
  • Breakdown frequency by machine with severity colour coding
  • Ticket creation vs resolution (gap analysis)
  • Spare parts consumption cost by category
  • Machine performance summary table with sortable health bars
  • Scheduled email reports & instant PDF / Excel export
See it in action

From Sensor to Insight — in Real Time

A four-stage data pipeline that connects your existing PLCs, sensors, and SCADA systems to actionable intelligence on every supervisor's screen.

1

Connect

IIoT gateway connects to your PLCs, sensors, and SCADA via OPC-UA, MQTT, and Modbus TCP — no rip-and-replace.

2

Monitor

Real-time data streams to edge compute with <40ms latency. Live sensor readings update every 4 seconds.

3

Analyse

AI models detect anomalies, predict failures, and surface root-cause hypotheses from historical patterns.

4

Act

Critical alerts auto-escalate, tickets auto-create, technicians get notified — production stays running.

Results That Show Up On Your P&L

Validated outcomes from real deployments. Every number tied to a specific operational lever.

+25%
OEE Improvement
Average increase within first 6 months through visibility, faster response, and PM compliance.
-40%
MTTR Reduction
Faster mean-time-to-repair via instant alerts, AI root cause, and spare-parts pre-staging.
-60%
Safety Incidents
Strong reporting culture + closure tracking drives down recordable incidents quarter-over-quarter.
-30%
Inventory Carrying Cost
ABC classification + AI reorder cuts overstock without sacrificing fill rate.
+35%
Technician Productivity
Less time searching for jobs & parts. More time fixing what actually needs fixing.
6-9 mo
Typical Payback Period
Most plants recover platform investment within 9 months through downtime reduction alone.

Industrial-Grade Architecture

Built on proven IIoT standards. Designed to integrate with what you already have — no rip-and-replace required.

IIoT Connectivity

Industrial protocols out of the box. Connect your floor without ripping out existing systems.

OPC-UA MQTT Modbus TCP REST API

Edge Compute

Local processing with cloud sync. No data leaves your facility unless you want it to.

Edge AI Local-first On-Prem Hybrid Cloud

Enterprise Security

Role-based access, encrypted comms, audit trail on every action. ISO/IEC 27001 aligned.

TLS 1.3 RBAC SSO Audit Log

Integrations

Plug into your existing stack. ERP, SCADA, MES — bidirectional sync via APIs and webhooks.

SAP Oracle MS Teams Slack

Built for Discrete & Process Manufacturing

From CNC job shops to multi-line automotive assembly — our platform adapts to your operations, not the other way around.

Automotive
Tier 1 & 2 suppliers, OEMs
Aerospace
Precision components
Heavy Machinery
Capital equipment
FMCG
Food, beverage, packaging
Electronics
PCB, semiconductor
Pharma
GMP-compliant ops

Ready to See It on Your Shop Floor?

Book a 30-minute walkthrough with our solutions team. We'll show you the platform live, discuss your specific operations, and build a custom rollout plan — no commitment.

Let's Connect

Speak with our IIoT solutions team. We typically respond within 2 business hours.

Head Office
ShopFloor Intelligence Pvt. Ltd.
Tidel Park, Anna Salai
Chennai, Tamil Nadu 600032, India
Working Hours
Mon–Sat · 9:00 AM – 7:00 PM IST
24/7 Support for Enterprise Clients

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