IoT Factory Monitoring Platform
Connected 200 CNC machines to a real-time monitoring platform with predictive maintenance alerts.
Where Pinnacle Group was stuck.
Pinnacle Group's manufacturing floor ran 200 CNC machines across two shifts. Machine downtime was tracked on paper, maintenance was scheduled by calendar rather than condition, and there was no way to correlate downtime patterns across machines or operators. Unplanned downtime was costing an estimated €420,000 per year in lost production.
How we solved it.
We deployed edge computing nodes on each machine to capture vibration, temperature, current draw, and cycle data at 100 Hz. Data flows via MQTT to a time-series database (InfluxDB), where anomaly detection models flag degradation patterns 48–72 hours before failure. A web dashboard gives shift managers a real-time floor view with drill-down per machine. Maintenance alerts are pushed to the maintenance team's mobile devices with a pre-populated work order.
Results that matter.
Unplanned downtime fell by 31 % in the first six months. Three machine failures were predicted and prevented before they caused production stoppage. Maintenance team productivity improved as planned interventions replaced emergency call-outs. Pinnacle Group is now extending the platform to their second facility.
first 6 months
across 2 shifts
before stoppage
before failure
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