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Create IOT products and solutions – Part 2

In my last article, I have talked about the challenges and oppurtunities of IOT industry. Now let’s talk about building an IOT product and  benefits of it in the market.

xl-2016-internet-of-things-1

How about building an IOT device?

Now let me also talk a bit about the process of building an IOT product. If you are thinking of building an air purifier, or a thermostat, or some smart lighting solutions for home, you are very likely to hit the first stumbling block as to how to go about the whole process. How to get a 3D design for the device, where to go for a prototype design, and how to get the electronics (the PCB part) done, and how to make the device talk and interact with various other devices like your mobile phone, etc.
 What you need is professional expertise in not one particular field, but many diverse fields. If you are a software engineer with some experience with coding, you will know writing software is not that difficult as all you need is a computer, and you could create wonders just sitting in home or office. Building a real, physical thing can be really tough & challenging. Not only it requires varied set of skill set, but also can cost much more to prototype, and test it out.

Steps to follow before going ahead

For the benefit of newbies to the field, I have listed down the steps generally followed in any IOT product development process.

  • Market Research
  • Conceptualization/Ideation
  • Design
  • Prototype (Schematic Design, Layout)
  • PCB Manufacturing
  • Procuring components & assembly of electronic circuitry
  • 3D printing of casing & outer facade of the product
  • Field Trials
  • Redesign & trials if needed
  • Marketing & Mass manufacturing

Loads of data is generated, but what to do with it?

Due to the large number of IOT devices around, it is quite as well expected that they will generate a huge volume of data. Question is how to make best use of the data captured, or how to make your device react to events triggered by actions of other users, or may be from the device owner himself through a mobile application.

Standards like the MQTT, AMQP, etc are the general protocols used for an IOT device or the cloud to communicate with each other. Both of them work on basic principle of publish/subscribe. The two parties subscribe to events, and whenever there is an update, or an occurrence of the event, the subscribing parties are notified.

Providers like Microsoft Azure, ABM, and AWS have all come up with their IOT platforms making it easy to monitor and control remote devices from click of a button. Being on the cloud, it gives IOT the ability to scale. The data being captured in the cloud can be analysed, and trends studied using Machine Learning algorithms and Artificial Intelligence.

Today it is possible to auto update the firmware of an IOT device without requiring any intervention from the customer.

How IOT will drive benefits for users?

Data generated from IOT devices are being continuously analysed and machine learning models are built to help in predictive analytics. Earlier emphasis was on preventive maintenance in industries, and anywhere else where machines were deployed. We used to ensure regular and timely checkups to ensure our machines are always in healthy state. But now with advancements in technology, based on the data captured, our machine learning prediction models can warn us in advance of a possible impending breakdown. A corrective action can be immediately triggered, and the machine is restored to good health much before breakdown.

emergency-notification-iot

Today IOT driven processes paves the way for improvements in existing processes leading to higher customer satisfaction & safety leading to better profits for businesses. Customers delight and an increasing affiliation are invaluable assets to any business, and when IOT is able to help the business achieve that, its relevance will never be in doubt. No wonder Gartner Research predicts there will be more than 20 billion IOT devices by the year 2020.
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Smart Manufacturing Dashboards: A Real-Time Guide for Data-Driven Ops

Smart Manufacturing starts with real-time visibility.

Manufacturing companies today generate data by the second through sensors, machines, ERP systems, and MES platforms. But without real-time insights, even the most advanced production lines are essentially flying blind.

Manufacturers are implementing real-time dashboards that serve as control towers for their daily operations, enabling them to shift from reactive to proactive decision-making. These tools are essential to the evolution of Smart Manufacturing, where connected systems, automation, and intelligent analytics come together to drive measurable impact.

Data is available, but what’s missing is timely action.

For many plant leaders and COOs, one challenge persists: operational data is dispersed throughout systems, delayed, or hidden in spreadsheets. And this delay turns into a liability.

Real-time dashboards help uncover critical answers:

  • What caused downtime during last night’s shift?
  • Was there a delay in maintenance response?
  • Did a specific inventory threshold trigger a quality issue?

By converting raw inputs into real-time manufacturing analytics, dashboards make operational intelligence accessible to operators, supervisors, and leadership alike, enabling teams to anticipate problems rather than react to them.

1. Why Static Reports Fall Short

  • Reports often arrive late—after downtime, delays, or defects have occurred.
  • Disconnected data across ERP, MES, and sensors limits cross-functional insights.
  • Static formats lack embedded logic for proactive decision support.

2. What Real-Time Dashboards Enable

Line performance and downtime trends
Track OEE in real time and identify underperforming lines.

Predictive maintenance alerts
Utilize historical and sensor data to identify potential part failures in advance.

Inventory heat maps & reorder thresholds
Anticipate stockouts or overstocks based on dynamic reorder points.

Quality metrics linked to operator actions
Isolate shifts or procedures correlated with spikes in defects or rework.

These insights allow production teams to drive day-to-day operations in line with Smart Manufacturing principles.

3. Dashboards That Drive Action

Role-based dashboards
Dashboards can be configured for machine operators, shift supervisors, and plant managers, each with a tailored view of KPIs.

Embedded alerts and nudges
Real-time prompts, like “Line 4 below efficiency threshold for 15+ minutes,” reduce response times and minimize disruptions.

Cross-functional drill-downs
Teams can identify root causes more quickly because users can move from plant-wide overviews to detailed machine-level data in seconds.

4. What Powers These Dashboards

Data lakehouse integration
Unified access to ERP, MES, IoT sensor, and QA systems—ensuring reliable and timely manufacturing analytics.

ETL pipelines
Real-time data ingestion from high-frequency sources with minimal latency.

Visualization tools
Custom builds using Power BI, or customized solutions designed for frontline usability and operational impact.

Smart Manufacturing in Action: Reducing Market Response Time from 48 Hours to 30 Minutes

Mantra Labs partnered with a North American die-casting manufacturer to unify its operational data into a real-time dashboard. Fragmented data, manual reporting, delayed pricing decisions, and inconsistent data quality hindered operational efficiency and strategic decision-making.

Tech Enablement:

  • Centralized Data Hub with real-time access to critical business insights.
  • Automated report generation with data ingestion and processing.
  • Accurate price modeling with real-time visibility into metal price trends, cost impacts, and customer-specific pricing scenarios. 
  • Proactive market analysis with intuitive Power BI dashboards and reports.

Business Outcomes:

  • Faster response to machine alerts
  • Quality incidents traced to specific operator workflows
  • 4X faster access to insights led to improved inventory optimization.

As this case shows, real-time dashboards are not just operational tools—they’re strategic enablers. 

(Learn More: Powering the Future of Metal Manufacturing with Data Engineering)

Key Takeaways: Smart Manufacturing Dashboards at a Glance

AspectWhat You Should Know
1. Why Static Reports Fall ShortDelayed insights after issues occur
Disconnected systems (ERP, MES, sensors)
No real-time alerts or embedded decision logic
2. What Real-Time Dashboards EnableTrack OEE and downtime in real-time
Predictive maintenance using sensor data
Dynamic inventory heat maps
Quality linked to operators
3. Dashboards That Drive ActionRole-based views (operator to CEO)
Embedded alerts like “Line 4 down for 15+ mins”
Drilldowns from plant-level to machine-level
4. What Powers These DashboardsUnified Data Lakehouse (ERP + IoT + MES)
Real-time ETL pipelines
Power BI or custom dashboards built for frontline usability

Conclusion

Smart Manufacturing dashboards aren’t just analytics tools—they’re productivity engines. Dashboards that deliver real-time insight empower frontline teams to make faster, better decisions—whether it’s adjusting production schedules, triggering preventive maintenance, or responding to inventory fluctuations.

Explore how Mantra Labs can help you unlock operations intelligence that’s actually usable.

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