Problem & audience
Plant directors and the maintenance, production, quality and energy teams.
- 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.
Solution modules
Monitoring & OEE
Tracks machine state, output, downtime and reasons; computes OEE by the definition the plant approves.
Condition-based maintenance
Analyses vibration, temperature and failure history; flags anomalies and raises inspection requests.
Quality & safety
Connects quality checks via data/cameras at suitable points; operators verify alerts.
Energy & dashboards
Tracks power by equipment, shift or product; reports trends and abnormal consumption points.
Process & data
Data to prepare
- 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.
Delivery conditions
The customer names a process owner, provides data cleared for use and a systems contact. CTC Smart Tech and the business team agree scope, test set, change handling and operating responsibility.
Infrastructure, equipment, licences, third-party integration and AI running costs are determined separately by discovery. This document is not a quotation or SLA commitment.
Pilot & acceptance criteria
- Choose one line or equipment group and survey the measurement points.
- Connect read-only, check data quality and time sync.
- Build dashboards and tune thresholds with operations staff.
- Cross-check on site; accept and plan the roll-out.
| Metric | How it is measured |
|---|---|
| Data coverage | Share of active measurement points and valid records versus expected. |
| OEE | Availability × Performance × Quality; recording method agreed before the pilot. |
| Useful alerts | Share of alerts verified as correct; time from detection to handling. |
| Energy | kWh per product unit, compared within the same product and operating conditions. |
Fix the pass threshold, sample size and measurement period before the pilot. These metrics are a proposed evaluation frame, not actual results or a performance commitment.
Governance & control
- 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.
Apply least privilege, data separation, action logs, retention/deletion rules and recovery. Test wrong-permission access, missing data and service interruption before handover.
Explore the solution in a working prototype
A design case study based on the Industrial IoT and CPSmart profile: monitoring measurement points, verifying alerts, assigning maintenance and closing the loop.
Frequently asked questions
Do we need to replace all machinery?
We first survey what existing PLC/SCADA can expose; sensors are only added where points are missing.
How soon do we get predictive maintenance?
It depends on data quality and failure history. Start with alert thresholds, then upgrade once enough data has accumulated.
Reference: CTC Smart Tech Industrial IoT & CPSmart capability profile. IoT/CPSmart capability documentation exists; the dashboards, assistant and apps in this kit are design prototypes not yet connected to real equipment. The process, pilot and acceptance sections in this kit are proposed designs to be confirmed per project.