# CTC Smart Tech — Industrial IoT · Plant Operations

Updated 09.2026
A design case study based on the Industrial IoT and CPSmart profile: monitoring measurement points, verifying alerts, assigning maintenance and closing the loop.

IoT/CPSmart capability documentation exists; the dashboards, assistant and apps in this kit are design prototypes not connected to real equipment.

## Business flow
- **Collect**: Log timestamp, equipment, measurement point and signal quality.
- **Verify**: Operations receives the alert and checks data reliability.
- **Assign**: Create an inspection request for the right technician.
- **Maintain**: Record the checklist, on-site result and evidence of work.
- **Close the loop**: The manager checks the result before closing the alert.

## Plant Operations workspace
Prototype dashboard with simulated records; states and process follow the solution design.
![Proposed prototype](https://solutions.smarttechctc.io/solutions/iot/screens/workspace.webp)

## Plant Operations assistant
Why does this measurement point need verification? Sourced simulated scenario; no LLM call.
![Proposed prototype](https://solutions.smarttechctc.io/solutions/iot/screens/assistant.webp)

## App Operator
Know which signal needs verification.
- Review alerts and measurement-point quality.
- Acknowledge receipt during the shift.
- Forward the inspection request to maintenance.

Module: Monitoring → Alerts → Maintenance request
Permissions: Acknowledges and reports state; cannot change thresholds or control machines.
![App](https://solutions.smarttechctc.io/solutions/iot/screens/operator.webp)
![App](https://solutions.smarttechctc.io/solutions/iot/screens/operator-detail.webp)
Try it: https://solutions.smarttechctc.io/demo/solutions/iot/operator/

## App Maintenance technician
Inspections with a checklist and a result.
- Receive the assigned work order.
- Confirm the inspection per the on-site procedure.
- Record the result and hand over for manager review.

Module: Work order → Checklist → Inspection result
Permissions: Assigned work only. Cannot close alerts before approval.
![App](https://solutions.smarttechctc.io/solutions/iot/screens/technician.webp)
![App](https://solutions.smarttechctc.io/solutions/iot/screens/technician-detail.webp)
Try it: https://solutions.smarttechctc.io/demo/solutions/iot/technician/

## App Plant manager
Close alerts on verified results.
- Track handling status and owners.
- Check maintenance results before closing an alert.
- Summarise causes and improvements.

Module: Dashboard → Maintenance → Close approval → Audit log
Permissions: Approves state within scope; OT control changes need a separate procedure.
![App](https://solutions.smarttechctc.io/solutions/iot/screens/manager.webp)
![App](https://solutions.smarttechctc.io/solutions/iot/screens/manager-detail.webp)
Try it: https://solutions.smarttechctc.io/demo/solutions/iot/manager/

## Sourced assistant
The simulated 78 °C signal exceeds the 75 °C sample threshold. Timestamp, sensor quality and site conditions must be checked per plant procedure; there is not enough evidence to conclude a failure. No control command is sent.
- SENSOR-DEMO v1: Simulated point: 78 °C with an illustrative 75 °C threshold. Not a recommended threshold for real equipment.
- WORK-DEMO v1: Sample work order; on-site verification follows the plant-approved maintenance procedure.
- POLICY-DEMO-OT: The prototype only tracks state; no PLC/SCADA connection and no control commands.

## Pilot roadmap
- Survey measurement points, protocols and the OT/IT boundary.
- Connect read-only; check timestamps, missing data and buffering.
- Run trial alerts; cross-check with operations/maintenance.
- Accept the confirm–handle–close loop and recovery capability.

## Acceptance
- Alerts store source, time and measurement-point quality.
- No closing without an inspection result.
- Delayed / disconnected data shows the correct state.
- The monitoring flow never generates control commands.

## Boundary & production conditions
No real sensor connection, no machine-operation instructions, no PLC/SCADA writes.
The prototype stores data in one browser; there is no backend, multi-user authentication, cross-device sync or real LLM. APIs, backend permissions, audit and integration must be accepted separately.
Source: CTC Smart Tech Industrial IoT & CPSmart capability profile
Case study: https://solutions.smarttechctc.io/case-study/iot-operations/

## Problem
- Machine data and shift reports are out of sync; downtime root causes are hard to trace.
- Reactive maintenance after failures causes disruption and is hard to plan.
- Energy use and quality defects are not tied to individual lines or batches.

## Input data
- Asset register, OT network diagram and existing device protocols.
- Shift data, good/defective output, downtime and maintenance history.
- Energy norms, metering diagram and system access rules.

## Deliverables
- Site survey, measurement-point catalogue and OT/IT connection architecture.
- Gateway, dashboards and alert set within the pilot equipment scope.
- Connection-loss test suite, operating guide and system maintenance schedule.
- Case study with screenshots, a workspace and sample apps for three roles; module/permission matrix and handover flow.

## Governance
- Early phases favour read-only connections, OT/IT network separation and role-based accounts.
- Internet loss requires an edge buffer; retention time and sync mechanism are part of acceptance.
- Forecast models need quality history; no lead-time commitments before measurement.