Factory-Wide IoT Implementation & Cloud Dashboard

The Challenge

The client operated a facility with over 20 legacy CNC and wire straightening machines. Because these machines lacked modern data-logging capabilities, the management team had zero visibility into real-time production metrics, temperature spikes, or power consumption.

This lack of data resulted in frequent, unplanned motor burnouts and unpredictable maintenance schedules, costing the company hundreds of thousands of rupees annually in halted production.

Our Solution

Varunah Engineering proposed a complete, non-invasive IoT retrofit using our proprietary Varunah Cloud architecture.

• Hardware Retrofitting: Installed industrial-grade temperature, vibration, and TDS sensors on critical machine components via ESP32 microcontrollers.
• Data Pipeline: Configured a secure, local MQTT broker to aggregate high-frequency sensor data before pushing it to the cloud.
• Varunah Cloud Dashboard: Deployed our custom cloud portal, allowing the client to set precise warning and critical thresholds for instant SMS and email alerts.

The Impact

Within the first 30 days of deployment, the predictive alerts successfully flagged two instances of abnormal motor vibration, allowing the maintenance team to replace bearings during a scheduled shift change rather than mid-production. The client now exports weekly PDF compliance reports directly from the dashboard for their ISO audits.