In the highly competitive landscape of the engineering industry, small and medium-sized enterprises (SMEs) face a number of crucial challenges to maintain their competitiveness. Among these, production monitoring and efficiency emerges as one of the most pressing.

Industrial IoT presents itself as a revolutionary solution, capable of radically transforming the way these companies operate and compete in the global marketplace. Want to find out how? Read on to learn more!

What is the situation of SMEs in the metal industry?

SMEs in the engineering sector are the beating heart of the Italian manufacturing industry. These companies face growing challenges: inflation, rising operating costs (especially energy), increasing competitiveness in foreign markets, and reduced operating margins (averaging less than 10 percent). In this context, the need to reduce waste and optimise processes becomes crucial. 

A modern, interconnected production monitoring system proves essential to overcome these challenges and maintain competitiveness. Lack of real-time visibility into machinery status, production times and overall plant efficiency is a significant obstacle to optimising production processes.

The adoption of industrial IoT solutions emerges as the most effective answer to these challenges. Advanced solutions such as the Zerynth IoT & AI Platform make it possible to overcome technological barriers, giving engineering SMEs the tools they need for a true digital revolution.

Real-Time Monitoring: The Key to Efficiency

Real-time production monitoring is one of the key opportunities arising from the adoption of an industrial IoT system. The Zerynth platform enables the collection and analysis of data from every stage of the production process, providing crucial information on:

• Operating status of machinery
• Production times
• Efficiency of individual processing steps
• Energy consumption

This immediate visibility enables managers to make informed and timely decisions, reducing downtime and optimising resource allocation.

Figure 1. “Productivity” dashboard of the Production Insights Zerynth APP.

Identification and Reduction of Bottlenecks.

One of the most significant benefits offered by an Industrial IoT system is the ability to quickly identify bottlenecks in the production process. Through the analysis of collected data, the Zerynth platform can highlight steps that slow down the entire production cycle. This information allows companies to take targeted action by implementing specific solutions to increase overall efficiency.

Predictive and Conditional Maintenance: how to avoid Problems

Predictive and conditional maintenance represents a quantum leap from traditional reactive or preventive approaches. 

With Industrial IoT systems, metalworking SMEs can constantly monitor the health of their machinery, identifying potential problems before they turn into failures. This proactive approach not only reduces unplanned downtime, but also optimises maintenance costs, extending the useful life of equipment.

Optimization of Energy Consumption

At a time when sustainability and energy efficiency have become top priorities, industrial IoT offers valuable tools for monitoring and optimising energy consumption. 

The Zerynth platform enables detailed tracking of the energy use of each machine and process, identifying possible areas of waste and opportunities for savings. This granular visibility enables companies to implement targeted energy efficiency strategies, reducing operational costs and environmental impact.

Full visibility on Production

Real-time monitoring is only the first step toward a true digital revolution in the engineering industry. To turn this visibility into a concrete competitive advantage, companies need advanced tools capable of analysing, interpreting and acting on the data collected. 

Designed to meet the specific challenges of engineering SMEs, Zerynth’s IoT & AI Platform integrates industrial IoT with powerful artificial intelligence algorithms, offering a complete digital ecosystem for production monitoring and process optimization. 

The Zerynth Platform not only provides real-time data, but transforms it into valuable insights that support the information needs of companies.

What are the Key Features of the Zerynth Platform?

The Zerynth platform offers a comprehensive suite of features designed specifically for the needs of the engineering industry:

1. Customizable Dashboards: Intuitive visualisations of the most relevant KPIs for industrial plant monitoring.
2. Advanced Analytics: Data analysis tools to identify trends and opportunities for improvement.
3. Intelligent Alerting: Real-time notifications for anomalies or critical situations.
4. Smart Reports: Generation of detailed reports to support decision-making.
5. IoT integration: Simplified connection of new and legacy machinery to the digital platform.

Engineering SME Efficiency with Zerynth: Real Cases

The adoption of industrial IoT through the Zerynth platform is not just about technology, but about business transformation. Metalworking SMEs that have embarked on this path have seen significant results:

• Reducing downtime by up to 30 percent
• Increased production efficiency by 15-20%.
• Optimization of energy consumption with savings of up to 25%
• Improving product quality and reducing waste

These results translate into a tangible competitive advantage, enabling companies to respond more quickly to market needs and offer higher quality products at lower costs.

Want to learn more about how the Zerynth Platform can support the process of production efficiency and optimization in your company? Download our dedicated white paper!