IIoT & Predictive Monitoring · MI-PM-01
Vibration-based Predictive Maintenance
Baseline vibration signature on three assets, ISO 10816 severity band, and an alert before a seeded fault progresses.
IIoT & Predictive Monitoring · MI-PM-01
Wireless vibration and temperature sensors on your motors, pumps and fans, a LoRaWAN gateway, and a condition-monitoring dashboard that warns you weeks before a bearing fails. Pilot on three assets in under a week.
- ₹63,000pilot BOM · hardware only
- 4 – 6 daysto a live pilot
- Intermediateintegration level
- 3validated providers
Why motors and pumps fail without warning
The problem
Rotating equipment fails without warning. Time-based maintenance replaces good bearings on schedule and still misses the pump that is about to seize. The cost is not the bearing, it is the line that stops for four hours while someone finds the spare.
- Failures show up as downtime, not as a work order
- Manual vibration rounds are monthly at best and depend on the technician
- Spares are stocked for everything because nobody knows which asset is next
- Insurance, OEE and delivery commitments all depend on assets nobody is watching
The solution
A magnetic-mount wireless sensor on each asset streams tri-axial vibration and temperature every few minutes. The gateway forwards it over LoRaWAN or BLE to a condition-monitoring dashboard that learns each asset's baseline, grades severity against ISO 10816 bands and alerts the maintenance lead when a trend crosses the line.
- Baseline signature per asset in the first 48 hours
- RMS, peak and temperature trends with ISO 10816 severity bands
- Alerts by email, SMS or WhatsApp with the asset name and trend chart
- Pilot proves an early warning on a seeded or known-degrading asset
Validated service providers
Validated by TwoElectrons and ranked by validation score: verified credentials, completed jobs on the platform and client ratings.
- Sample Provider D — Chennai · Condition monitoring & PdM · ★ 4.9 · 17 jobs
- Sample Provider E — Pune · PLC / Modbus integration, OEE · ★ 4.7 · 12 jobs
- Sample Provider F — Ahmedabad · Process instrumentation · ★ 4.6 · 9 jobs
Provider listings are samples pending live registrations.
Pilot BOM and cost
Reference hardware to run the pilot. Unit costs are indicative Indian market prices for the component class.
| Qty | Item | Unit cost | Line |
|---|---|---|---|
| 3× | Wireless vibration + temperature sensor tri-axial, magnetic mount, LoRaWAN/BLE | ₹16,000 | ₹48,000 |
| 1× | LoRaWAN Bluetooth gateway | ₹13,500 | ₹13,500 |
| 1× | Condition-monitoring dashboard RMS, peak, temperature trend; free tier | Free tier / open source | — |
| 1× | Magnetic mounts & thread-lock | ₹1,500 | ₹1,500 |
| Pilot BOM total | ₹63,000 |
POC BOM cost only — hardware for a pilot. Installation, integration and provider services are quoted separately. Request for Quote
How wireless vibration monitoring works
- Mount. Magnetic-mount three sensors on bearing housings; no wiring, no shutdown.
- Connect. Plug in the gateway; sensors join the LoRaWAN network automatically.
- Baseline. Run 48 hours to learn the normal signature of each asset.
- Alert. Set thresholds; the dashboard raises an alert when a trend leaves the band.
Pilot architecture
3× Vibration + temp sensors (tri-axial, magnetic mount) → LoRaWAN / BLE gateway (Ethernet or Wi-Fi backhaul) → Cloud LNS + CM platform (The Things Stack / ChirpStack) → Maintenance dashboard (alerts: email · SMS · WhatsApp)
Pilot architecture: three assets, one gateway, dashboard on a free-tier LNS. Scales by adding sensors, not infrastructure.
Business case: downtime, maintenance cost, asset life
Ranges are typical figures reported for this class of solution; your pilot establishes the numbers for your plant.
- 30–50% less unplanned downtime (industry-reported range for PdM programmes)
- 10–25% lower maintenance cost (fewer scheduled replacements of healthy parts)
- 2–6 wks typical early warning (bearing wear and imbalance trends)
- < 1 week to a live pilot (three assets, one gateway)
Who this is for: Maintenance heads, Plant managers, Auto components, Pharma & process, Textiles & paper, Any plant with critical motors, pumps, fans or compressors.
Illustrative case study
Illustrative scenario · not a client reference
A tier-2 auto-component plant near Pune (illustrative)
Set-up. Three assets — a 45 kW compressor, a coolant pump and a paint-shop exhaust fan — fitted with wireless vibration sensors, one gateway, dashboard on a free-tier LNS. Pilot run by the in-house maintenance team with a validated provider on call.
What happened. In week three the compressor's RMS trend climbed two ISO bands over five days. The team scheduled a bearing change at the weekend shutdown instead of losing a shift. The plant extended monitoring to twelve assets after the pilot.
- Pilot budget: ₹63,000 hardware
- Time to first alert: 3 weeks
- Avoided stoppage: 1 shift (est.)
FAQ
Do the sensors need wiring or a shutdown to install?
No. They are battery-powered and magnetic-mount; installation takes minutes per asset and the machine keeps running.
Which machines are suitable for a pilot?
Any rotating asset with a bearing housing: motors, pumps, fans, blowers, compressors and gearboxes. Pick assets whose failure stops production.
How is this different from a handheld vibration meter?
A handheld gives a reading when someone visits. Wireless sensors give a trend every few minutes, so a slow rise in vibration is caught between rounds.
What does the ₹63,000 cover?
Only the pilot hardware for three assets on a free-tier dashboard. Integration, installation and provider services are quoted separately after a Request for Quote.
Can it connect to our CMMS or SAP PM?
Yes. The dashboard exposes MQTT and REST, so alerts can create work orders in a CMMS during the scale-up phase.
