We partnered with a major global manufacturer to deliver an end-to-end digital asset management solution across its mission-critical processes. The focus was high-quality, real-time data from robust, scalable LoRaWAN sensors for predictive maintenance. The outcome was decisive: wireless vibration monitoring scaled from a trial of 50 sensors to more than 2,000 across Australia, Asia Pacific and the United States, preventing catastrophic failures and cutting unplanned downtime.
Predictive maintenance using sensors and connected networks prevents failures before they stop production. The highest-value use cases in an industrial factory or plant include:
- Vibration monitoring for early fault detection in pumps, motors and conveyors
- Temperature and pressure tracking to prevent overheating and breakdowns
- Automated lubrication alerts to minimise wear and tear
- Water, energy and gas metering for efficient resource use and to avoid production loss
- Asset tracking to locate equipment and support maintenance scheduling
The Need for Digital Transformation in Manufacturing
To remain competitive amid the inherent cyclicality of global demand, industrial manufacturers, particularly in steel production, must invest in digital transformation. By adopting technologies like digital twins, IoT and advanced analytics, they can enhance agility, optimise operations and improve product quality, ensuring resilience and long-term success.
Unlocking LoRaWAN for Remote Asset Monitoring
The manufacturer embarked on a significant digital transformation and ESG initiative to deploy mass-scale IoT and smart sensing, feeding data into advanced predictive analytics and AI tools. The goal was highly granular, real-time datasets that pinpoint potential issues with machines and equipment and improve operational efficiency. With accurate 24/7 datasets, the organisation now informs its predictive and intelligent digital maintenance systems.
To start the journey, the company installed several LoRaWAN gateways at one of its major port facilities, connected to the SLA-backed MeshedX LoRaWAN network server for assured network uptime.
The organisation had already installed cellular, WiFi and Bluetooth networks and begun IoT sensing with some proprietary sensors. LoRaWAN was seen as the better answer for connectivity at difficult-to-reach machine locations, given its extended coverage and deep penetration inside factories and sub-floor environments. As a global standard with a large supplier ecosystem, LoRaWAN also allowed the organisation to host multiple sensing use cases on the same network, a major competitive advantage and return-on-investment driver.
The Machine Vibration Case Study
After piloting multiple use cases, including water metering, temperature, level and pressure monitoring, and asset tracking with trend analytics and automated alerts, the company identified its highest-impact application: granular vibration monitoring of mission-critical machines and motors. Powered by the private MeshedX LoRaWAN network, the highly scalable solution delivers early-warning insights that prevent catastrophic failures, cut unplanned downtime and safeguard production.
Intrinsically safe industrial IoT sensors detect issues early and trigger condition-based maintenance, preventing breakdowns and minimising downtime. The company invested in a trial of the Advantech WISE-2410 vibration sensors to provide 24/7 monitoring of rotating machines and motors at a couple of locations. We partnered with Advantech to run the trial and demonstrate value against the customer's machine performance and end-of-life failure prediction needs.
The Advantech WISE-2410 Vibration Sensor
The Advantech WISE-2410 is a wireless, battery-powered LoRaWAN condition-monitoring sensor designed for predictive maintenance in industrial environments. It enables real-time vibration and temperature monitoring to detect early signs of mechanical failure. With onboard analytics and predictive-maintenance support, it reduces unplanned downtime, extends equipment life and lowers maintenance costs, without the need for complex installations.
Results at Scale
As real-time data started to flow, the organisation quickly scaled the use case from 50 to more than 2,000 Advantech vibration sensors across multiple sites in Australia, Asia Pacific and the United States.
The key benefits of LoRaWAN were factory-wide wireless coverage at very low cost, deep wireless penetration indoors at machine locations, and reduced maintenance costs, as the sensors are easy to install and need no SIM cards or data plans to send data securely. The MeshedX LoRaWAN network server is backed by SLAs on network uptime and comprehensive technical support.
The lesson is consistent with what we see across asset-intensive industries. Once teams see measurable reductions in downtime, industrial condition monitoring scales quickly, from a handful of machines to thousands of assets on one secure network.
