Introduction

Partnering with a leading OEM in gearboxes, inverters, and motors, the client faced challenges with reactive maintenance, limited real-time insights, and high operational costs. The Maintenance Department Head aimed to boost equipment uptime, cut maintenance expenses, and enhance operational efficiency.

The Solution Summary

The client needed a robust IoT solution to enable real-time monitoring and predictive maintenance for their equipment, including motors, gearboxes and inverters. They aimed to transition from reactive to proactive maintenance practices, optimize equipment performance and provide superior customer support through timely data-driven insights.

The Solution Summary

Trinetra Tsense implemented a comprehensive IoT and cloud-based remote monitoring solution tailored to the client’s needs:

• IoT Sensors Installation: Advanced sensors were installed on motors, gearboxes and inverters to capture real-time data on temperature, vibration, load and operational efficiency.
• Cloud-Based Data Analytics: Data from sensors was aggregated on a cloud platform, where machine learning algorithms analyzed trends and patterns to predict potential failures and optimize maintenance schedules.
• Remote Monitoring Dashboard: A user-friendly dashboard provided Maintenance Department Heads with real-time insights into equipment performance, health status, and operational metrics from any location.
• Predictive Maintenance Alerts: Automated alerts notified maintenance teams and customers of impending issues, enabling proactive maintenance actions to prevent equipment failures.
• Customer Portal Integration: Integration with a customer portal allowed clients to access real-time data, receive alerts and schedule maintenance, thereby improving their support experience.

Results

The solution delivered significant benefits to the client:

• Reduced Downtime: Real-time monitoring and predictive maintenance reduced unplanned downtimes, enhancing equipment uptime and productivity.
• Cost Savings: Transitioning to predictive maintenance lowered maintenance and labor costs while extending equipment lifespan.
• Enhanced Equipment Performance: Continuous monitoring optimized equipment performance, ensuring peak efficiency of motors, gearboxes and inverters.
• Improved Customer Satisfaction: Access to real-time data and proactive maintenance alerts strengthened customer relationships by enhancing support and reliability.
• Scalable Solution: The cloud-based platform ensured scalability, enabling the client to expand monitoring capabilities seamlessly as their product range and customer base grew.

Trinetra Tsense’s IoT and cloud solutions shifted the OEM to proactive maintenance, improving uptime, cutting costs, and enhancing customer satisfaction. Advanced analytics and real-time insights enabled operational excellence and set the stage for scalable growth and innovation.

Introduction

A leading OEM in the floor cleaning machine industry faced challenges managing their fleet across diverse locations efficiently.

The Problem Outline

The client needed a solution to address operational inefficiencies caused by a lack of real-time tracking and unreliable maintenance schedules. They aimed to improve fleet management, optimize maintenance efforts, and enhance customer service by providing actionable insights into machine performance.

The Solution Summary

To validate the effectiveness of their IoT solution, Trinetra Tsense initiated a pilot program at Bangalore Airport. They equipped two-floor cleaning machines with IoT devices that tracked critical performance metrics. These metrics included machine location, idling time, running time and battery levels.

The data collected underwent rigorous validation to ensure accuracy and reliability before Trinetra Tsense considered a wider implementation.

Results

• Improved Operational Efficiency: Real-time tracking and detailed usage data enabled better fleet management, reducing idle time and improving overall efficiency.
• Predictive Maintenance: Accurate data on machine usage and battery levels facilitated predictive maintenance, minimizing downtime and extending machine lifespan.
• Enhanced Customer Service: Customers gained insights into machine performance, enabling proactive equipment management and enhancing satisfaction.
• Scalability and Cost Savings: The scalable solution allowed gradual deployment across the entire fleet, optimizing operations and reducing costs through data-driven decision-making

Trinetra Tsense’s IoT solution revolutionized floor cleaning machine management, using real-time data and predictive analytics to shift from reactive to proactive operations, significantly improving efficiency, maintenance predictability, and customer satisfaction for industrial OEMs.

Introduction

Trinetra tSense, was approached by a client who is a prominent player in the drilling rig industry, specializing in manufacturing and operating state-of-the-art drilling machines and mobile rigs. With a commitment to innovate and excel, they sought to enhance their operations and improve the longevity of their drilling rigs with an eye on better ROI.

The Problem Outline

The client faced several critical challenges in their drilling rig operations at various locations:

• Monitoring Complex Machine Parameters: They needed to closely monitor machine health via the temperature, oil level, vibration, and RPM of their drilling machines to ensure optimal performance and prevent unexpected breakdowns and costly downtime.
• Automation for Error Reduction: Human errors in monitoring and maintenance processes were causing costly disruptions and issues. The client required remote monitoring and an automated solution to mitigate these errors and ensure accuracy in operations.
• Optimization of Maintenance: To improve productivity and reduce downtime, the client needed data for a comprehensive understanding of maintenance requirements with scheduling and a way to predict and prevent faults and downtime.

The Solution Summary

Our IoT solution empowered with telematics technology provider stepped in with a remote machine monitoring system with data analytics tailored to cater to the drilling rig industry. Here’s how we addressed the client’s pain points:

• Comprehensive Data Monitoring: The implementation of sensors and IoT devices to monitor critical parameters such as temperature, oil level, vibration, RPM, and more provides real-time data on the health of drilling machines. This ensures optimal performance and minimizes unexpected breakdowns and costly downtime.
• Machine Performance Insights: Your data analytics system offers real-time insights into machine performance, enabling the client to optimize operations, increase productivity, and extend the operational lifetime of their drilling rigs.
• Predictive Analytics: By analyzing historical data, your IoT-based solution helps the client identify trends in faults, allowing for proactive maintenance and reducing downtime and maintenance costs. This predictive approach is essential for efficient and cost-effective operations.
• Better Security: The inclusion of features like fuel monitoring and location tracking adds an extra layer of security. This not only prevents fuel theft and misuse but also helps in tracking the location of mobile drilling rigs, ensuring their safety.

Result

The implementation of our remote machine monitoring system yielded notable results:

• Asset Performance Knowledge: The client gains a deep understanding of their drilling rig assets’ performance. This data-driven insight enables them to optimize maintenance schedules and reduce expenses related to warranties, leading to cost savings.
• Enhanced Brand Value: Improved machine quality and reliability enhance the client’s brand value, ensuring customer retention and loyalty. This can lead to increased market share and revenue.
• Better Operational Efficiency: Real-time monitoring and data analysis streamline operations, reducing labor costs and speeding up performance analysis and report generation. This efficiency improvement is crucial in a competitive industry.
• Real-time Monitoring & Security: The ability to monitor fuel consumption, machine vibration, machine hours, and location status in real-time allows for timely adjustments, improving overall operational efficiency and security.
• Data-Driven Decision Making: Embracing a data-driven approach for decision-making empowers the client to make more informed choices, plan effectively, and strategically invest resources where they are needed most.
• Expert Collaboration: Collaboration with your domain expertise and solution experts ensures that the client continues to receive value from your solution as their business evolves.

Trinetra’s IIoT solution and IoT platform not only addressed pressing challenges but also provided valuable insights, cost savings and improved asset performance, giving the client a competitive edge in the drilling rig industry. To harness the power of IoT in industrial operations, please contact us.

Introduction

The client, a renowned generator manufacturer and supplier for retail chain stores, operates across the entire country. Their objective was to outsource a remote generator monitoring system for their diesel generators, which are installed in diverse geographic locations.

The Problem Outline

The client wanted to monitor the multi-site locations of the end-customer’s generators. They needed a remote diagnostic tool to monitor the engine running hours and fuel level of each generator set. The proposed system should help them to know about maintenance details to improve productivity via remote monitoring and analytics. They wanted to add value to their product range and for product development with the data obtained from remote assets.

The Solution Summary

The IoT application for remote assets proposed, can instantly monitor critical parameters along with its trends, which is for making easy data-based (informed) decision making. The software application can monitor on 24×7 basis, in real-time, on the IoT platform provided by us. The benefits of the solution provided are:

• Time and Cost Saving for the company
• Value Addition by improved productivity
• Helps to know the trend of faults and improvement done
• Increase the machine health and reduce the maintenance which comes under warranty
• Time and Cost Saving for the company
• Performance of the assets easily analysed and reports compiled instantly

Outcome / Result

• Remote monitoring offers 24×7 visibility of assets on remote sites,
• Instant notification/alerts on abnormalities and hazards
• Remote monitoring of machine health increases uptime
• Helps in better energy/fuel management of assets for stakeholders
• Overall improved brand value and ensures customer retention

This customised automated IIoT solution when deployed runs on a single unified software platform which is cloud hosted. Equipped with purpose-based sensors, it remotely monitors various parameters within the generator monitoring system to generate data for remote diagnostics and analytics. It improves both product development for the OEM and post sales experience.

Introduction

Our client, a prominent player in the manufacturing industry with a focus on cold forming machines, faced significant challenges in monitoring and maintaining their complex machines. These machines, ranging from mono-layer to 7-layer extruders, are each equipped with multiple Variable Frequency Drives (VDSs) and four Programmable Logic Controllers (PLCs). Dissatisfied with their existing IoT solution, they sought a more reliable monitoring solution, specifically tailored for their industry.

The Problem Outline

• Multifaceted Machinery: The client operated various extruder machines, each with its unique complexity, making real-time monitoring a challenge.
• Size & Complexity: The sheer size and intricacy of the machines, coupled with multiple VDSs, posed difficulties in monitoring and maintenance.
• Automation Requirements: With four PLCs in each machine, the client required an automated monitoring system to streamline operations and reduce manual intervention.
• Unsatisfactory IoT Solution: The client’s existing IoT solution couldn’t meet expectations, prompting the need for a more reliable alternative solution.
• Predictive Maintenance: The client wanted a solution c offering predictive maintenance and comprehensive data gathering for informed decision-making.
• Customized Reports: Industry-specific customized productivity reports were essential for the client to optimize their operations effectively.

The Solution Summary

• Data-Driven Decision Making: Our IoT solution provided real-time remote monitoring of critical parameters, enabling data-driven decision-making for timely interventions.
• Improved Machine Quality & Lifetime: By analyzing machine performance in real-time, the solution contributes to enhancing machine quality and extending their operational lifespan.
• Trend Analysis for Faults & Improvement: The system facilitated trend analysis, allowing the client to identify patterns of faults and areas for improvement.
• Timely Reporting: Reports, which previously took weeks to compile, were generated within minutes, offering quick insights into asset performance.
• Real-time Monitoring: The solution allowed the client to monitor each machine’s running, and idling, providing a comprehensive view of asset health.

Results

• Enhanced Asset Performance: The performance of the assets significantly improved, allowing the client to proactively address potential issues.
• Reduced Customer Complaints: Customer complaints related to machine performance decreased, contributing to higher customer satisfaction.
• Elevated Brand Value: The overall brand value of the client improved as a result of optimized machine performance and reduced downtime.
• Improved Asset Visibility: The client gained improved visibility over their assets, leading to better control and management.
• Time and Cost Savings: The implementation of the IoT solution resulted in notable time and cost savings for the client.

In conclusion, the successful deployment of Trinetra’s data-driven IoT solution effectively addressed the client’s need for remote machine monitoring in manufacturing,

Introduction

Our esteemed client is a leading player in the manufacturing sector, specializing in Railway Construction Equipment. Their Product Development Centre (PDC) with a commitment to innovation and excellence, constantly strives to enhance the quality and performance of its machinery.

The Problem Outline

The Product Development Centre (PDC) faces challenges in real-time monitoring of crucial parameters for outdoor railway construction equipment. This lack of visibility into factors like temperature, oil level, vibration, RPM, running time, idle time, predictive maintenance, load factor, accurate working location, fuel consumption, and more hinders data-based decision-making. The absence of instant insights into performance trends, fault identification, and necessary improvements leads to time-consuming processes, impacting productivity and customer satisfaction. There’s a pressing need to enhance overall machine quality and lifecycle through actionable data.

The Solution Summary

To address these challenges, we proposed a customized IoT solution for the railway construction equipment industry — Heavy Equipment Asset Management. This solution involved monitoring crucial parameters (temperature, oil level, vibration, RPM, running hours, electrical parameters, and fuel consumption) using the Trinetra application. This data-driven approach offered timely insights, enabling informed decision-making. Beyond data collection, our solution, developed in collaboration with domain experts, took a holistic approach to address pain points and deliver tangible value.

For example, in the remote monitoring solution for a concrete batching plant, the Trinetra application, equipped with wireless technology, improved asset visibility, leading to time and cost savings, ultimately enhancing productivity.

Railway construction equipment that can be monitored:

• Excavators: Hydraulic Excavators, Crawler Excavators & Wheeled Excavators
• Bulldozers: Crawler Bulldozers
• Backhoes: Backhoe Loaders
• Cranes: Mobile Cranes & Tower Cranes
• Tamping Machines: Ballast Regulator & Tamping Machine
• Concrete Batching Plants: Mobile Concrete Batching Plants & Stationary Concrete Batching Plants
• Pavers: Asphalt Pavers & Concrete Pavers
• Graders: Motor Graders
• Track Maintenance Machines: Rail Grinders & Rail Lifters
• Railway Inspection Cars: Track Inspection Cars
• Tunnel Boring Machines (TBMs): Main Beam TBMs & Shield TBMs
• Railroad Tie Replacers: Tie Removers & Tie Installers
• Rail Welding Machines: Flash Butt Welding Machines & Gas Pressure Welding Machines
• Rail Drills: Portable Rail Drills & Vertical Rail Drills
• Track Renewal Trains: Ballast Cleaning Machines & Track Laying Machines
• Railway Maintenance Vehicles: Rail Inspection Vehicles & Rail Cleaning Vehicles
• Railway Signal Systems: Signaling Equipment &Train Control Systems
• Railway Safety Equipment: Trackside Warning Systems & Level Crossing Systems

Our IoT solution can be implemented across these machines to monitor and optimize their performance, providing valuable insights for efficient operation and maintenance.

Results

• Performance Improvement: Noticeable enhancement in overall asset performance.
• Customer Satisfaction: Substantial reduction in equipment functionality complaints.
• Brand Value Enhancement: Improved asset performance and proactive maintenance elevate brand value.
• Operational Efficiency: Swift analysis of asset performance streamlines decision-making and operational processes.
• Time and Cost Savings: Reports generated within minutes, leading to significant time savings. Monitoring results in cost savings.
• Proactive Maintenance: Real-time monitoring identifies potential faults, facilitating proactive maintenance.
• Improved Visibility: Enhanced visibility over asset status contributes to improved operational efficiency.
• Data-Driven Insights: Trinetra application provides valuable data-driven insights for informed decision-making.
• Overall Productivity Gain: Holistic monitoring and maintenance approach contribute to a sustained increase in overall productivity.

This collectively underscores the successful impact of the IoT solution on PDC’s operations, affirming its value in the competitive industry of construction machines manufacturing.

Introduction

In a rapidly changing telecommunications environment, our client, a leading satellite services subsidiary, pioneers innovative IoT solutions for the telecom sector. They serve diverse clients, with a specific focus on end customers utilizing generators in remote locations like construction sites and mines. Using satellite communication, our IoT solution significantly transforms their operations.

The Problem Outline

The client’s pain points were twofold. First, they needed to monitor critical parameters and obtain data on the DG sets, including temperature, oil level, vibration and RPM, which is to ensure the machines’ optimal performance. Second, they wanted to improve the quality and lifetime of the DG sets by gaining insights into their performance, faults, and trends. They were in search of a comprehensive IoT solution tailored to their needs.

The Solution Summary

To tackle these challenges, our client turned to Trinetra Gateway, a highly capable IoT solution designed to integrate with various makes and models of DG sets, with a particular focus on Cummins, Kirloskar and Deep Sea Electronics. This solution empowered our client to tap into the full potential of IoT in the telecom industry. This innovative solution enabled the real-time monitoring of essential data, such as running hours, electrical parameters and fuel consumption, through a user-friendly application compatible with mobile devices.

Our generator monitoring solution incorporated a data-driven approach, leveraging domain experts and solution experts to provide valuable insights to the business. It facilitated the quick analysis of asset performance and the generation of reports, a process that previously took weeks. It also allowed for the monitoring of machine running, idling and charging status, empowering our client’s customers to make timely and informed decisions.

Results

• Improved Asset Performance: By closely monitoring temperature, oil levels, vibration, and RPM, the client’s customers saw a noticeable improvement in DG set performance.
• Reduced Customer Complaints: The proactive monitoring of critical parameters led to a decrease in customer complaints related to asset failures and downtime.
• Enhanced Brand Value: The ability to provide reliable and uninterrupted power solutions boosted the overall brand value of our client, solidifying their position as a pioneer in offering IoT solutions for the telecom industry.
• Ensured Customer Retention: Satisfied customers, thanks to the improved performance of their DG sets, resulted in higher customer retention rates.
• Improved Visibility over Assets: The ability to monitor DG set parameters in real-time provided our client’s customers with enhanced visibility over their assets, further emphasizing the role of IoT in the telecom sector.
• Time and Cost Savings: Quick and efficient data analysis translated into significant time and cost savings, making the IoT solution highly cost-effective for our client.

Through the implementation of an IoT solution, our client effectively addressed the challenges of optimizing asset performance and reducing customer complaints. Our comprehensive solution provided enhanced visibility, cost savings and an undeniable competitive edge for the client in the swiftly evolving technological landscape

 

Introduction

Trinetra tSense, a leading IoT solutions provider, was approached by a prominent manufacturing company in the cleaning industry. The company’s Vice Chairman sought a dependable solution to tackle the issues related to monitoring and managing their extensive fleet of cleaning equipment.

The Problem Outline

The manufacturing company faced several challenges, including the need to remotely monitor the location, running hours, and usage level of their diverse range of cleaning equipment, which included scrubbers, vacuums, and rider models. They aimed to enhance their services to end clients through real-time monitoring and reporting. Although they had a well-established CRM and ERP system, they required a specialized hardware and API solution to seamlessly integrate with their existing systems.

The Solution Summary

Understanding the client’s unique requirements, Trinetra tSense proposed a GPS Tracking & Fleet Management solution tailored to their needs. The solution included IoT hardware devices capable of accurately tracking the location, operational hours, and usage patterns of each cleaning equipment unit. Trinetra tSense provided a comprehensive API support package, enabling seamless integration with the client’s existing CRM and ERP systems.
To cater to the client’s preference for developing their own software, Trinetra focused on delivering robust hardware and data collection capabilities. The solution was adaptable to both battery-operated and diesel-operated equipment, encompassing the client’s entire fleet.

Outcome / Result

• Real-time Visibility: Vice Chairman gained real-time insight into fleet’s location, usage patterns, and maintenance needs.
• Proactive Decision-Making: Enabled efficient resource allocation and proactive decision-making.
• Enhanced Customer Service: Accurate equipment status and usage information improved customer service.
• Operational Efficiency: Significant enhancement in operational efficiency achieved.
• Software Development Leverage: Company utilized its software development capabilities due to hardware and API support.
• Deployment Goals Met: Successfully deployed 1000 to 3000 devices annually for their machines.
• Industry Leadership: Strengthened the company’s position as an industry leader in the cleaning equipment segment.

Our tailored IoT solution empowered the manufacturing company to overcome their challenges and achieve operational excellence in managing their cleaning equipment fleet. The successful collaboration showcased the power of IoT technology in addressing specific industry pain points and delivering impactful solutions. We offer our clients customisable IIoT solutions hosted on a single unified software platform.

Introduction

The client that approached us is a reputed caffeine manufacturer with customers spread all over the country with Pan-India operations. They were looking at outsourcing a remote machine monitoring system with IoT tech for their manufacturing unit.

Business Requirements

The client wanted visibility on their machines’ production and also downtime when it occurs. Another pain point of the client was unaware if their machines are running overtime and at what RPM. If RPM is not maintained the quality of the powder from grinding the coffee beans will be affected and they needed to monitor that aspect of their machinery.

The client also needed to know how the employees are handling the machinery like the centrifuge and dryers, which is a grey area for them. They also required remote diagnostic tools and data to plan and schedule maintenance for all the heavy-duty machines that they were not able to do presently.

The Solution Summary

We at Trinetra TSense were able to provide a solution to the client with our cloud-based machine monitoring system which will make it convenient for them to monitor different parameters that are required by the client. The web-based asset monitoring and management platform can show the current values of parameters of each machine or group of machines used in the manufacturing of caffeine. The IoT application can instantly monitor critical parameters and its trends, making it easy for data-driven (informed) decision-making. The IoT based application can monitor on 24×7 basis, in real-time, hosted on the IoT platform provided by tSense.

Benefits

• Improved productivity and uptime
• Finds the trend of both faults and improvement
• Trigger alerts and notifications on fault identification
• Increases machine health and reduces the maintenance cost
• Performance of machines analysed and reports compiled in minutes.
• Monitoring can record the hours a machine has been operated, stopped or is idle.
• High visibility on utilisation of the machines helps to maintain quality of the caffeine powder
• Can automate manual process and improve the efficiency of machines.

Outcome / Result

• Remote monitoring of machine health improves uptime and productivity
• Remote monitoring gives 24×7 visibility of assets/machinery, even at remote locations
• Instant notification/alerts on set limits, abnormalities and hazards to prevent downtime
• Helps in better energy/fuel management of assets for stakeholders
• Overall improved quality, value addition and ensures customer satisfaction

We offer our clients customisable IIoT solutions hosted on a single unified software platform. Dedicated sensors monitor the various parameters to generate data for remote diagnostics and data analytics. Contact us for more details on IIoT solutions.

Introduction

The client is a major player in the transport and logistics industry, and they have a large fleet of electric vehicles deployed. They have ambitious growth plans and have approached us for an IoT software solution to improve productivity and efficiency by tracking and monitoring the electric vehicle fleets in real-time to solve some of the pain points and to scale up operations.

Business Requirements

The Trinetra team had a discussion with the client to identify the pain points that needed to be resolved. This also helped to decide on the customization needed in the IoT software we proposed for their EV fleet management. The client has about 31 EV trucks operating in four different locations. Each truck will have to transport the EV bikes from warehouse to warehouse within cities and the vehicles will be operated 24/7.

A few of the trucks are contracted vehicles, and the remaining are their own vehicles. The client was looking for a one-stop solution for managing all the trucks. The client needed to know the trips taken by each vehicle, when the trip started and ended. Stoppages for more than 10 minutes should trigger alerts to stakeholders in real-time. They required up-to-date info and real-time updates using the IoT fleet management software. The solution has to be integrated with their current system and had to track the vehicles being rented.

Trinetra Solution

The Trinetra IoT Fleet Management Platform uses technologies like GPS, IoT sensors, and data analytics to help companies become efficient and profitable by streamlining their fleet management, monitoring, and tracking operations. Real-time updates help decide on the shortest routes and get the driver’s location. The IoT fleet management software sends pop-up messages to stakeholders and offers trip updates. The Geo-fencing and other related features enable location-based alerts, non-compliance alerts, and help to enable a seamless vehicle journey.

The IoT technology used here helps in automating tasks for achieving better operational efficiency, safety, maintenance, and theft prevention, and helps to decrease instances of theft. It helps in drawing out EV charging plans for optimizing energy usage and timely charging of vehicles. This maximizes the reliability and stability of operations. The IoT fleet management system also generates various types of reports for fleet maintenance, tire management, etc. It helps gain insight into EV drivers’ behavior and energy consumption to optimize EV fleet management.

Benefits

• Monitor & Optimize energy management
• Optimize operations with visibility of over 30%
• High visibility on fleet movement with location tracking
• Managers get automated real-time alerts
• Keeps driver engaged for less violation on multiple aspects
• Fleet Management rules can be inducted and monitored as per requirement of the project
• Expectation based monitoring and event based reporting
• Evolving hardware and software updates