Industrial
Predictive maintenance, OEE telemetry and condition monitoring for production lines - without the rip-and-replace of your existing controls.
IoT-WorkS retrofits vibration, current and environmental sensors onto existing plant, then applies machine learning to flag developing faults before they stop the line. Legacy PLCs stay in place: we bridge Modbus, OPC UA and Profinet into a modern data layer rather than replacing controls you already trust.
Where we deploy
3 typical use casesVibration-based predictive maintenance
Wireless vibration sensors on motors, pumps and gearboxes; the AI Telemetry engine flags failures 7-11 days early.
HSE guidance on work equipment maintenance (hse.gov.uk)Energy & utilities sub-metering
Per-line electricity, compressed-air and water sub-metering. Identify the ten biggest waste drivers in the first month of monitoring.
Legacy PLC integration
Modbus, OPC-UA and Profinet bridges into modern IoT dashboards. Existing PLCs stay; you gain the data layer above them.
OPC UA standard (opcfoundation.org)How does predictive maintenance actually predict a failure?
A wireless sensor on a motor, pump or gearbox samples vibration and temperature continuously. The platform learns that asset baseline signature over its first weeks, then watches for the drift that precedes mechanical failure - bearing wear, imbalance, misalignment, looseness. Because the baseline is per asset rather than a generic threshold, the engine flags a developing fault typically 7 to 11 days before it would stop the line.
- Per-asset baseline learned from live data, not a catalogue threshold
- Bearing wear, imbalance, misalignment and looseness signatures detected
- Warning lead time long enough to schedule the fix into planned downtime
- No production interruption to install: sensors mount externally
Do we have to replace our PLCs or SCADA system?
No, and we would advise against it. Existing controls stay exactly as they are and we add a data layer above them. Modbus, OPC UA and Profinet bridges read what the PLCs already publish and forward it to the telemetry platform, so you gain dashboards, history and anomaly detection without revalidating a control system that works. OPC UA in particular gives a vendor-neutral path off proprietary formats.
OPC UA standard (opcfoundation.org)How does condition monitoring support maintenance obligations?
Work equipment must be maintained in efficient working order and in good repair, and maintenance records must be kept where they exist. Continuous condition data gives you a defensible record of the state of each asset over time, plus evidence of when an intervention was raised and completed - considerably stronger than a signed checklist, and available without waiting for the next inspection round.
HSE guidance on work equipment maintenance (hse.gov.uk)What does a first deployment usually look like?
Most plants start with the assets whose failure hurts most: a handful of critical motors, pumps or compressors, plus sub-metering on the highest-consumption lines. That is enough to prove the baseline and surface the first anomalies within weeks, and sub-metering typically identifies the ten biggest energy waste drivers in the first month. Coverage then extends asset by asset rather than as one large capital project.
Every vertical runs on the same engines: AI Telemetry for sensor data, Engineering services for hardware + firmware + integration, the same platform for dashboards, alerts and compliance exports. The vertical changes the asset class and the regulatory frame; the stack underneath doesn't.
Frequently asked questions
- How much notice does predictive maintenance give before a failure?
- Typically 7 to 11 days for rotating equipment such as motors, pumps and gearboxes. That window is deliberately long enough to order parts and fold the repair into planned downtime rather than reacting to an unplanned line stop.
- Do sensors need to be wired into the machine?
- No. Vibration and temperature sensors mount externally and run on battery power with multi-year life, communicating over LoRaWAN or NB-IoT. Installation does not interrupt production and does not touch the machine control circuit.
- Can you read data from our existing PLCs?
- Yes. We bridge Modbus, OPC UA and Profinet into the telemetry platform, so the PLCs and SCADA you already run stay in place and keep doing their job while you gain history, dashboards and anomaly detection above them.
- What can sub-metering tell us that our utility bill cannot?
- A single bill hides where energy goes. Per-line electricity, compressed-air and water sub-metering attributes consumption to specific assets and shifts, which is what makes the biggest waste drivers visible, usually within the first month of monitoring.
- Is this suitable for a plant with older machinery?
- Older plant is often the best case. Externally mounted sensors need no support from the machine itself, so equipment with no native telemetry gains condition monitoring without modification, and the assets most likely to fail are usually the ones being retrofitted.
Tell us about your industrial project.
A local engineer will reply within one working day with a recommended sensor mix, gateway architecture and a rough deployment timeline.