Manufacturing Sensor Solutions

Transform Production Operations with Intelligent IoT Networks

8-12% OEE Improvement Through Sensor Integration

Comprehensive Manufacturing IoT Solutions

Industry 4.0 sensor technology for complete production optimization

Production Line Monitoring

Real-time visibility into production flow and bottlenecks

  • Photoelectric Sensors: Product counting & positioning
  • Proximity Sensors: Equipment cycle monitoring
  • Vision Systems: Assembly verification
ROI Impact: 15-20% throughput increase
  • Real-time OEE dashboards
  • Bottleneck identification
  • Production rate optimization

Quality Control Automation

Automated inspection and defect detection systems

  • Laser Scanners: Dimensional measurement
  • Machine Vision: Surface defect detection
  • Load Cells: Weight verification
ROI Impact: 90% defect reduction
  • 100% inspection coverage
  • Automated reject handling
  • Quality trend analysis

Predictive Maintenance Systems

Equipment health monitoring and failure prediction

  • Vibration Sensors: Bearing & motor analysis
  • Thermal Cameras: Hot spot detection
  • Acoustic Sensors: Ultrasonic leak detection
ROI Impact: 40% reduction in downtime
  • Failure prediction algorithms
  • Maintenance scheduling optimization
  • Spare parts management

Environmental Control Systems

Production environment and cleanroom monitoring

  • Temperature/Humidity: Climate control
  • Particle Counters: Air quality monitoring
  • Pressure Sensors: Cleanroom differential
ROI Impact: 100% compliance assurance
  • ISO 14644 compliance
  • Automated HVAC adjustment
  • Contamination prevention

Inventory & Material Tracking

Real-time material flow and inventory management

  • RFID Tags: Asset & WIP tracking
  • Barcode Scanners: Product identification
  • Weight Sensors: Bin level monitoring
ROI Impact: 25% inventory reduction
  • Real-time location tracking
  • Automated reordering
  • Supply chain visibility

Safety & Security Systems

Comprehensive worker and equipment safety monitoring

  • Light Curtains: Machine guarding
  • Gas Detectors: Hazardous atmosphere monitoring
  • Emergency Stops: Safety interlock systems
ROI Impact: 70% incident reduction
  • Zone-based safety monitoring
  • Lockout/tagout integration
  • Incident analytics

Our Manufacturing IoT Implementation Approach

Industry 4.0 transformation through intelligent sensor deployment

Factory Assessment

Comprehensive production analysis to identify automation opportunities and sensor requirements

System Integration

Seamless integration with ERP, MES, SCADA systems via OPC UA, REST APIs

Edge Computing

Local processing for real-time control with cloud connectivity for analytics

AI Analytics

Machine learning models for predictive quality and maintenance optimization

Industrial-Grade Technology Stack

Enterprise-ready sensors and protocols for demanding production environments

  • Inductive, capacitive, photoelectric proximity sensors
  • 2D/3D machine vision systems
  • Laser triangulation & time-of-flight sensors
  • MEMS accelerometers for vibration analysis
  • Thermal imaging cameras

  • OPC UA for MES/ERP integration
  • EtherNet/IP & PROFINET for PLCs
  • IO-Link for smart sensors
  • MQTT for cloud connectivity
  • REST APIs for enterprise systems

  • ISA-95 Enterprise Integration
  • ISO 9001 Quality Management
  • IEC 61131 PLC Programming
  • ISO 13849 Machine Safety
  • IIoT Consortium Standards

Why Choose AEQ for Manufacturing IoT?

8-12%

OEE Improvement Target

< 1s

Response Time

24/7

Remote Monitoring

Zero

Production Disruption

Our manufacturing IoT approach offers:

  • Solutions for automotive, F&B, pharma sectors
  • Legacy equipment integration capability
  • Comprehensive training support
  • Continuous optimization services

Ready for Industry 4.0 Transformation?

Schedule a comprehensive smart factory assessment

Factory Walk-Through

OEE Analysis

Roadmap Development

Schedule Your Manufacturing IoT Assessment