Smart Manufacturing: IoT Digital Twin for Predictive Maintenance

A.P Co. operated 20 factories. When a CNC machine failed, it halted the line for hours, costing thousands. They had sensors, but the data was trapped in silos. Factory managers relied on reactive repairs. They needed a centralized 'Digital Twin' to visualize operations and predict failures before they happened.

GTEMAS built a dedicated team of IoT and Data engineers. Data Ingestion: We connected 500+ machines to Azure IoT Hub using MQTT. The Twin: We built a 3D visualization of the factory floor using Three.js, overlaid with real-time sensor data (temperature, vibration). AI Decisioning: We trained anomaly detection models on historical failure data. The system now alerts maintenance teams 48 hours before a predicted bearing failure.

The system empowered factory managers to make data-driven decisions. The 'Digital Twin' became the central command center for operations, now being rolled out globally.