IIoT Solutions DeliveringSignificant Benefits

Solution

Shortly after installation, two chutes on separate dates triggered notifications of rising velocities. Upon inspection, the maintenance team identified build-up at the back and sides of the feeders, leading to increased vibration. Preventative cleaning of the chutes was performed, averting potential structural failures.

Solution

IIoT sensors were installed within the operating power generation facility. The technology detected a start of vane pump failure within six (6) weeks of installation.

Solution

The Wireless vibration monitoring system was installed on their conveyor network. These sensors, integrated with predictive analytics, flagged an emergent condition on a conveyor’s pulley. The condition monitoring team confirmed the sensor's alert, allowing for early detection and proactive maintenance, thus preventing a potential failure and supporting their data-driven decisions process.

Solution

The IIoT sensors autonomously identified a fault pattern in the Motor DE bearing, specifically pinpointing the type of bearing fault (BPFO). This early detection allowed for timely, data-driven maintenance decisions, preventing the possibility of extensive damage and affirming the value of the IIoT solution.

Solution

An IIOT sensor detected the vibration increase almost immediately after the plant restarted and sent an immediate alert. The condition monitoring team confirmed the issue, identifying ore buildup inside the pulley itself. They issued a repair notice to remove the buildup, preventing potential failure and avoiding an estimated $300k in operational and mechanical losses.

Solution

In order to ensure the system was monitored overall and that vibration energy was not being transferred from elsewhere, IIoT sensors were rapidly deployed throughout this and other auxiliary equipment. Within 13 days, they detected a brush failure in the generator.

Solution

IIoT sensors were installed within their facility detecting the fault in the motor bearing within one (1) week. A basic $65 bearing was replaced during a regular maintenance shutdown instead of having a $5,000 gearbox fail during peak usage.

Solution

The Wireless Vibration IIoT sensors were installed within their facility and detected a bearing outer race failure within six (6) weeks of installation.

Solution

Deployed in just days, the Timesheet module seamlessly onboarded internal teams and external contractors, automating reminders and simplifying entry workflows to achieve 95% compliance by week’s end. Real-time dashboards now display actual vs. budget metrics instantly, empowering managers to reduce overruns by up to 14% and realise over >$200k in annual savings.

Solution

We replaced spreadsheet-based workflows with the integrated, mobile-enabled project controls suite—centralising baseline schedules, cost ledgers, resource plans, and risk registers into a single dashboard. Field crews now log excavation and processing metrics in real time, while automated alerts surface variances against plan. This shift delivered a 20% uplift in schedule adherence, cut budget overruns by >10%, and unlocked roughly $1 million in annual cost savings. All at only one site.