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Unlocking OEE with IoT Production Monitoring: From Symptom to Cause
When OEE (Overall Equipment Effectiveness) falls below expected levels, the question is always the same: where does the problem really come from? Understanding whether the cause lies in machine availability, production speed, or product quality is not straightforward. IoT production monitoring helps identify these issues quickly, guiding managers to efficient production decisions and improving industrial production efficiency across the factory. In this article, you will discover how to transform OEE from a simple indicator into an operational tool, capable of guiding rapid decisions, reducing downtime, and improving collaboration across departments. How to understand why OEE is below target A common
From Breakdown Chaos to IoT Predictive Maintenance
In many manufacturing companies, the maintenance department still operates in a constant state of emergency. When a machine stops, a race against time begins to repair it, causing delays and inefficiencies in production. Implementing IoT predictive maintenance can transform this scenario. Why is maintenance always in emergency mode? Even when a preventive plan exists, it is often ineffective for several reasons: Rigid interventions – based on fixed intervals rather than real machine data. Premature or delayed maintenance – some tasks are performed too early, others only after a breakdown, causing machine downtime. Lack of real-time monitoring – managers have
From Data Darkness to Full Visibility: How IoT Production Monitoring Improves Machine Efficiency
IoT production monitoring is essential to understand whether a company is getting the most out of its investments. With the right production monitoring solutions, it’s possible to move from fragmented data to a single, unified view, helping balance workloads, reduce downtime, and plan precisely, ultimately supporting real time production monitoring and production optimization. How can you tell if machines are being used optimally? In this case study, a metalworking company had just invested in new machining centers, but managers were asking: "Are we really making the most of our machines?" The main issue was fragmented reporting: data was
How to Improve Production Efficiency with Equipment Health Monitoring, Predictive Maintenance, and Industrial IoT
Keeping machinery running continuously and at optimal performance is one of today’s main challenges in manufacturing. Equipment Health Monitoring, powered by IoT solutions and predictive algorithms, is a strategic lever to cut costs and optimize processes. What is the impact of unplanned downtime on production? Every unexpected machine stoppage generates costs, delays, and cascading inefficiencies. Even in simple production lines, such as a press or a conveyor belt, downtime has an immediate impact on productivity. Digital monitoring enables real-time detection of anomalies. Through sensors and software, data is collected on cycles, speed, output, pauses, and operating conditions. These data
How to Boost Productivity by Reducing Downtime: A Packaging Industry Case Study
Discover how an Italian SME in the packaging industry transformed its operations—shifting from a reactive to a proactive approach—thanks to the Zerynth platform for machine maintenance monitoring. What was the issue: why was production slowing down? A packaging machinery company in Italy was facing a critical challenge: No real-time visibility on machine status Difficulty identifying prolonged downtime Reactive instead of preventive maintenance Increasing waste of time and resources Production monitoring was entirely manual. The result? Slow decision-making, emergency fixes, and a negative impact on production optimization. How does smart rule-based monitoring work? To increase productivity and reduce downtime, the
Stationary elevators? How to reduce downtime in your industry with intelligent monitoring and predictive maintenance
Why is it important to avoid elevator and freight lift downtime? Elevators are essential infrastructures in residential, commercial, and industrial buildings. In industries, freight lifts and hoisting systems are crucial for internal material transport. A sudden failure or prolonged downtime causes disruptions, inefficiencies, safety risks, and negative impacts on productivity and work quality. For this reason, adopting predictive maintenance elevators solutions is becoming a priority for companies aiming to reduce unexpected stoppages. How does traditional maintenance work and what are its limitations? Traditional maintenance of elevator systems relies on scheduled interventions at fixed intervals (preventive maintenance). Main limitations: It
The Invisible Challenge of Traceability: Digitizing Production in the Plastics Industry
How to tackle the traceability issue in plastic manufacturing with a digital solution?Thanks to the Zerynth Platform, a company in the plastic molding sector overcame the challenges related to tracking production cycles by integrating machines, management systems, and the cloud. Keep reading to learn more! What was the operational context? The most common scenario in production environments where the process is continuous and low-variability is one in which a single machine carries out the entire operation defined by a single work order without interruptions and within a single production shift. What was the main challenge? One of the most
Why Is Monitoring the Cold Chain Crucial for Food Companies?
Monitoring temperature throughout the entire cold chain is essential to ensure food safety, reduce waste, and comply with regulations. Even brief interruptions can compromise quality, health, and company reputation. What Is the Cold Chain and When Does It Start? The cold chain encompasses the processes and tools that keep perishable foods at controlled temperatures, from production to sale. Each stage of the food supply chain — processing, transportation, storage, and distribution — must guarantee consistent and traceable thermal conditions, making cold room temperature monitoring and cold storage monitoring systems vital components of effective cold chain monitoring. What Happens If
Traceability and Production Optimization in a Metalworking Company
Discover how an SME digitalized production control, improved production optimization, and reduced machine downtime with Zerynth. Keep reading to learn more! What are the challenges in production? An Italian SME, specialized in manufacturing metal products for the furniture industry, faced difficulties in understanding its production performance on a daily and especially monthly basis. The main need was a production monitoring solution that would digitalize every phase, including activities carried out at manual factory workstations, to improve scheduling and reduce downtime. Main challenges: Difficulty in understanding daily and monthly production trends. Need to automate data collection from machines and manual
Integrating Zerynth with Corporate MES and ERP Systems: How and Why to Move in This Direction
The integration between the Zerynth Industrial IoT & AI Platform and MES and ERP systems represents a valuable opportunity for the digital transformation of manufacturing companies. By leveraging artificial intelligence in Industry 4.0, SMEs can optimize production and enhance energy monitoring efficiency. In this article, we explore how the Zerynth platform, a Manufacturing Intelligence Platform, seamlessly integrates with MES and ERP systems to optimize and improve production processes while strengthening business management. Keep reading to discover all the details! The Zerynth Manufacturing Intelligence Platform Zerynth connects production operations with enterprise systems, integrating MES, MOM, SCADA, EAM, and IIoT functionalities
