Optimizing Packaging Line Maintenance

A project was done in a packaged food manufacturing plant. The key issue faced was frequent machine downtimes, costing approximately INR 50 lacs annually. To address this, the project team implemented a Predictive Maintenance System using IoT sensors on critical machinery. These sensors monitored real-time performance metrics and alerted the maintenance team of potential failures. The solution included integrating IoT platforms with existing ERP systems. As a result, unplanned downtimes reduced by 40%, saving INR 30 lacs annually and enhancing overall production efficiency. Additionally, the data collected enabled better resource planning, extended machinery lifespan and uninterrupted continuous manufacturing.