Client Overview
A steel manufacturing unit located in Jharkhand, India, operating high-temperature furnaces, rolling mills, and heavy-duty industrial equipment. The client aimed to modernize their plant operations with real-time data and intelligent control systems.
Our Approach
Our strategy focused on:
- Installing IIoT sensors across production units
- Creating a scalable edge-to-cloud data architecture
- Building real-time dashboards and anomaly alerts
- Implementing predictive analytics for asset performance
Challenge
The plant lacked visibility into real-time equipment status and environmental data. Operations relied on periodic manual checks, causing delays in decision-making and frequent downtime due to undetected anomalies.
IIoT (Industrial Internet of Things)
India
Key pain points included:
- No centralized platform for equipment monitoring
- Unexpected machinery breakdowns
- Inconsistent quality due to poor control over parameters
- High energy usage with no tracking
Solutions Delivered
IIoT Sensor Network Deployment
Installed sensors to capture temperature, vibration, speed, and energy data across production units.
Edge-to-Cloud Data Infrastructure
Enabled local processing and seamless cloud sync using scalable gateway and communication protocols.
Real-Time Monitoring & Alert Dashboards
Provided instant visibility with drill-down dashboards and configurable anomaly detection alerts.
Predictive Maintenance & Energy Analytics
Used data trends for failure prediction and energy optimization to reduce downtime and costs.
Technologies Used
Business Impact / Results
Qematic’s IIoT implementation delivered measurable improvements:
What Our Clients Say
"QeMatic's RPA team transformed our manual loan processing system. What once took days now happens in hours. Their deep platform knowledge and process-driven approach helped us reduce turnaround time by over 60% while staying fully compliant."
“We engaged QeMatic to integrate AI with our existing automation efforts. The results were outstanding — predictive quality control and demand forecasting brought a new level of intelligence to our operations. They truly understand the future of automation."
"QeMatic's Time and Motion Study uncovered hidden inefficiencies in our patient onboarding flow. Their insights led to a 30% improvement in staff productivity and better patient experience. The free consultation alone was eye-opening."
Key Highlights (Summary Box)
| Metric | Before | After |
|---|---|---|
| Equipment Visibility | Limited | 80%+ Real-Time |
| Unplanned Downtime | High (biweekly) | Reduced by 60% |
| Energy Tracking | Manual | Automated + Alerts |
| Maintenance Planning | Reactive | Predictive Model |
