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Engineering Solution

Smart Factory IIoT & Predictive Asset Health

Continuous vibration telemetry, bearing fault FFT spectral diagnostics, automated CMMS asset work orders, and real-time OEE factory intelligence.

Smart Factory IIoT & Predictive Asset Health
Smart Factory IIoT & Predictive Asset Health Engineering Spec

Smart Factory IIoT & Predictive Asset Health

Field Tested in Turkey & Pakistan
Operational Challenge

The Problem

Unheralded mechanical bearing seizure, shaft misalignment, and unbalance cause multi-million rupee production halts, ruined drive assets, and emergency shift overtime.

Engineering Approach

Nexus Solution Overview

We install high-frequency tri-axial vibration accelerometers and smart edge gateways that stream spectral acceleration, velocity, and demodulated peak data to predictive AI models and centralized plant CMMS dashboards.

System Capabilities

Wireless Tri-Axial Vibration & Surface Temperature Edge Sensors
FFT Spectrum, Time Waveform & Bearing Enveloping Analysis (ISO 10816)
Cloud-Connected CMMS for Automated Preventive & Predictive Work Orders
Real-Time Machine Monitoring System (MMS) with Live Andon Displays
Overall Equipment Effectiveness (OEE) Availability & Performance Telemetry
MTBF (Mean Time Between Failures) & MTTR Reliability KPI Dashboards

Hardware & Software Platforms Integrated

Nexus MachinePulseSKF EnlightIFM Efector SensorsNode-RED & MQTT GatewaysGrafana Enterprise Dashboards

Measurable Business Benefits

Unplanned Outages-75%

Elimination of catastrophic mechanical bearing breakdowns.

Maintenance Cost-30%

Savings achieved by eliminating unnecessary calendar-based overhauls.

Asset Lifespan+45%

Prolonged rotating equipment service life through early anomaly remedy.

Typical Industrial Applications

Textile Spinning Ring Frames & Carding Cylinder Bearings
Cement Raw Mill & Kiln Drive Gearbox Condition Telemetry
Petrochemical Pump Stations & High-Pressure Gas Compressors
Continuous Steel Rolling Mill Chock & Roller Assemblies
INDUSTRIAL AUTOMATION & CONTROL PANEL SPECIALISTS

Partner with Pakistan's trusted engineering team for turnkey automation, PLC/SCADA retrofits, custom MCC panels, and precision energy metering across Faisalabad, Lahore, Karachi, and nationwide manufacturing plants.

Turnkey S7/VFD Panels
SCADA & IoT Telemetry
24/7 Field Support
PEC Registered Team
Call / WhatsApp: +92 300 7121985

380+ Plants Optimized · Textile, Cement, FMCG & Dairy Facilities Across Pakistan