Industrial IoT: Industry 4.0 Transformation and Accelerators

Manufacturers have invested heavily in plant-floor automation, yet many still face challenges in unlocking the full value of their machine data. Innova Solutions’ Industrial IoT solution bridges this gap by connecting PLCs to the AWS cloud, enabling near real-time visibility into operational metrics and laying the foundation for scalable, data-driven manufacturing. This offering empowers organizations to modernize their operations, improve equipment performance, and drive innovation through advanced analytics and AI.

Features

• Edge Gateway Connectivity: Seamlessly connect PLCs to the cloud via edge gateways, enabling secure and scalable data ingestion.

• Real-Time Metrics Dashboards: Deliver near real-time OEE/OPE metrics to executives and plant supervisors for informed decision-making.

• Multi-Plant Scalability: Establish a framework for connecting multiple plant locations to a centralized cloud infrastructure.

• Comprehensive Risk Assessment: Evaluate current IoT infrastructure and provide detailed risk reports with remediation support.

• Multi-PLC Support: Compatible with Allen Bradley, Siemens, Rockwell, Brankamp, and other leading PLCs.

• Advanced Visualization: Leverage AWS Managed Grafana for intuitive dashboards and performance monitoring.

Benefits

• Boost Operational Efficiency

Achieve up to 45% improvement in Overall Equipment Effectiveness (OEE) by identifying bottlenecks and optimizing machine performance in near real-time.

• Reduce Downtime with Predictive Maintenance

Cut unplanned downtime by up to 50% through proactive analysis of shift effectiveness, machine setup issues, and operator training gaps.

• Improve Product Quality and Traceability

Reduce defect rates by 25–35% by tracing issues back to raw materials, metallurgy, and machine conditions - enabling faster root cause analysis and corrective actions.

• Accelerate Innovation Cycles

Shorten product development timelines by up to 40% using machine twins and simulation models to test production line changes before implementation.

• Scale Across Locations

Deploy a unified IIoT framework across multiple plants, enabling centralized monitoring and consistent performance benchmarking.

• Empower Decision-Makers

Provide executives and plant supervisors with real-time dashboards and actionable insights, improving responsiveness and strategic planning.

Key AWS Components

AWS IoT Core, Amazon S3, Amazon Athena, Amazon Kinesis, Amazon CloudWatch, AWS Managed Grafana.