SES-005 Manufacturing IoT retrofit · predictive maintenance

1996 production line with predictive maintenance — no digital interfaces, ROI in 12 months.

93%

savings vs. replacement

€ 86,400

annual savings

−86%

unplanned downtime

18 h

avg. warning time before failure

Baseline

6 machines (built in 1996), analog signals only (4–20 mA, thermocouples, PT100), no digital interfaces. 32 hours unplanned downtime per month, €8,500/month production loss. Machine replacement: €1,200,000. Maintenance was purely reactive — after failures.

Solution: custom IoT sensor nodes

Hardware (custom PCB per machine type)

ESP32 ultra‑low‑power data logger
16‑channel 24‑bit ADC expansion
Inputs: 4–20 mA, 0–10 V, thermocouples, PT100
MEMS accelerometer for vibration analysis
Wi‑Fi + MQTT communication
IP65 enclosure, 24V DC supply

Firmware & analytics

High-rate ADC sampling up to 10 kHz
On-device FFT vibration analysis (ESP32 DSP)
0–500 Hz spectral analysis of bearing points
Rule-based early warning with < 100 ms latency
MQTT telemetry: raw data + KPIs + alarms
OTA update support

Architecture

6 custom IoT nodes (ESP32 · ADC · MEMS · IP65)

↓ MQTT over Wi‑Fi

RabbitMQ AMQP broker (MQTT via plugin)

↓

Node.js pipeline + FastAPI REST

↓

TimescaleDB + InfluxDB (high‑frequency vibration)

↓

React dashboard FFT spectrum · trends · predictive score · alarms

Cost savings

Direct comparison

Machine replacement

€ 1.200.000

Solvetronix

€ 84.000

You save

€ 1.116.000

Savings

93 %

Typical ROI: < 12 months

Results after 6 months

9 of 12 failure patterns intercepted by early warning

Avg. warning time: 18 hours before failure

Unplanned downtime: 32 h/month → 4.5 h/month (−86%)

Monthly savings: €7,200 (from €8,500 to €1,300)

Installation per machine: 4 hours, no production stop

First complete digital machine history

Energy consumption: −12% through optimization

Spare parts ordering possible 3 weeks in advance

Analog machine, no data, high downtime?

We bring your existing system into Industry 4.0 — without replacing machines.

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