Client
A global industrial equipment manufacturer operating multiple large-scale production plants across Asia, Europe, and North America.
Client Background
The client manages complex, continuous manufacturing operations with thousands of machines, sensors, and control systems. Over the years, the lack of centralized visibility, predictive insights, and IoT-driven automation limited their ability to optimize asset performance and maintain consistent production throughput.
Client Challenge
The client faced significant operational inefficiencies due to disconnected machine systems, lack of real-time analytics, and inconsistent data from OT and IT environments. Production teams relied on manual logs for tracking equipment performance, making early fault detection impossible.
Maintenance schedules were time-based rather than condition-based, resulting in unnecessary downtime or equipment failures. Multiple vendor-specific protocols across legacy machines restricted integration. The absence of a scalable IoT framework prevented adoption of predictive maintenance, automated quality checks, digital dashboards, and Industry 4.0 capabilities.
The organization needed an engineering solution that seamlessly connected operational technology (OT) with enterprise IT systems, enabling a smart, data-driven factory ecosystem.
Xevyte Solution
Xevyte deployed an end-to-end IoT engineering framework that integrated OT sensors, PLCs, SCADA systems, and equipment controllers into a unified data pipeline. A secure industrial IoT gateway aggregated machine telemetry, providing real-time visibility into vibration data, temperature, cycle time, and production metrics.
Our engineering team built a cloud-native analytics platform that processed telemetry, detected anomalies, and generated predictive maintenance alerts. Digital twins were developed for critical machines to simulate behavior and forecast failures. Role-based dashboards provided actionable insights to plant managers, maintenance teams, and operations leadership.
All integrations adhered to ISA/IEC 62443 guidelines, ensuring strong industrial cybersecurity. Scalable microservices made the solution easily extendable across additional plants globally.
Business Impact
Key Capabilities Delivered