Deploying IoT Solutions and Video Analytics in Manufacturing

About project

In today’s fiercely competitive global market, production efficiency has become a decisive factor for business success. However, many factories still operate with outdated systems and legacy machinery that lack internet connectivity, creating data “blind spots” that hinder effective KPI management. To overcome this challenge, our company has implemented IoT Solutions and Video Analytics to digitize production operations, enable real-time equipment monitoring, and enhance overall productivity.

Root Cause of the Challenge: Lack of Data

The core issue lies in the inability of machines to transmit data. This leads to several urgent needs:

• Efficient data collection from production lines at minimal cost
• Real-time monitoring of employee and machine activities
• Live data analysis to evaluate performance
• Periodic reporting and alerting capabilities for management

This is not merely a technological problem—it’s an operational and economic challenge that demands a smart solution without requiring full equipment replacement.

Breakthrough Deployment: Integrating IoT and AI

The key strategy is to collect indirect data from external sources (sensors and video) to infer machine status and performance.

Dual-Channel Data Collection (Camera & Sensors)

• Video as a new data source: By leveraging existing surveillance cameras, video becomes a primary data stream for operational insights.
• Smart sensors: Devices measuring light, temperature, sound, and low-frequency vibration are installed on or near machines. Changes in these indicators provide clear evidence of machine activity—whether running, idle, or malfunctioning.

Cloud-Based Processing with AWS Technologies

Raw data is processed through a powerful, flexible, and cost-effective cloud infrastructure:

Comprehensive Benefits of IoT Solutions and Video Analytics

The integration of sensor-based IoT data and visual video analytics has delivered outstanding results:

• Efficient and cost-effective monitoring: A modern solution that minimizes installation costs without deep intervention into existing machinery
• Operational transparency: Video analytics provide detailed oversight of employee and machine activities, reducing time waste and improving process compliance
• Real-time management: Instant data processing and analysis offer a panoramic view of production status
• Preventive alerts: The system automatically detects and warns of issues (e.g., overheating, prolonged downtime), enabling technicians to respond quickly and reduce disruptions

Thanks to IoT Solutions and Video Analytics, the company has shifted from intuition-based management to data-driven decision-making. Monitoring, control, and strategic planning have significantly improved, leading to optimized production and sustainable cost savings. This project underscores the indispensable role of IoT, AI, and Computer Vision in modernizing even the most traditional manufacturing facilities.