WORKFLOX Services
Catch Equipment Failure Before It Stops the Line
Predictive Maintenance & Production Data Software
Unplanned downtime is the most expensive line item on a factory floor. We build the monitoring dashboards and predictive maintenance software that flag failing equipment before it halts production.
The Challenge
Why Equipment Downtime Keeps Surprising Manufacturers
- ✗Maintenance is scheduled by calendar, not by actual equipment condition
- ✗Sensor data from machines exists but is never turned into alerts
- ✗Production-line data lives in disconnected PLCs with no central view
- ✗No historical trend view to spot gradual equipment degradation
- ✗Plant managers find out about failures after the line has already stopped
Our Approach
What We Build
- ✓Data pipelines pulling telemetry from PLCs, sensors, and SCADA systems into a central platform
- ✓Predictive maintenance models that flag anomalies before failure
- ✓Real-time equipment monitoring dashboards for plant and maintenance managers
- ✓Production-line analytics tracking throughput, downtime, and OEE
- ✓Automated alerts routed to maintenance teams via SMS, email, or app
Use Cases
What We Build For You
Predictive Maintenance Dashboards
Monitor vibration, temperature, and runtime data from production equipment to flag machines trending toward failure.
OEE (Overall Equipment Effectiveness) Tracking
Automate availability, performance, and quality metrics into a live OEE dashboard instead of manual shift reports.
Warehouse & Logistics Equipment Monitoring
Track forklift, conveyor, and sorting equipment health across a distribution center from a single dashboard.
Cold Storage & Refrigeration Monitoring
Continuously monitor industrial refrigeration units with alerts before temperature excursions damage inventory.
Energy Consumption Analytics
Aggregate power draw data across production lines to identify inefficient equipment and reduce energy costs.
SCADA Data Bridging to Cloud
Bridge on-premise SCADA and PLC data to cloud dashboards accessible to management outside the plant floor.
Our Process
Step-by-Step Development Process
01
Plant Data Audit
We assess your existing PLC, SCADA, and sensor data sources and identify gaps in monitoring coverage.
02
Pipeline & Platform Architecture
We design the data pipeline bridging plant-floor systems to a central cloud or on-premise platform.
03
Dashboard & Model Build
We build monitoring dashboards and, where data history allows, predictive maintenance models.
04
Alerting Integration
We route threshold and anomaly alerts to maintenance teams through their existing communication channels.
05
Rollout & Model Tuning
We deploy across additional lines and continuously tune models as more equipment history accumulates.
Technology
Our Stack
A typical industrial iot solutions project here uses MQTT, OPC-UA, AWS IoT Core and Node-RED. We confirm the final choices with you at scoping, based on the systems you already run and the constraints you have.
FAQ
Frequently Asked Questions
Do you install or manufacture the sensors on our machinery?
No. We are a software engineering company: we build the data pipelines, predictive models, and dashboards. Physical sensor installation and any custom industrial hardware is handled by your equipment vendor or a specialized industrial hardware integrator; we then connect to that hardware in software.
Can you integrate with our existing SCADA or PLC systems?
Yes. We commonly bridge OPC-UA and Modbus data from existing SCADA and PLC systems into cloud platforms, adding modern dashboards and alerting without replacing your existing plant-floor control systems.
How accurate is predictive maintenance software, realistically?
Accuracy depends heavily on sensor data quality and history. We are upfront that early models flag anomalies and trends rather than predicting exact failure dates. Accuracy improves as the model accumulates more historical failure data from your specific equipment.
Do you work with legacy factory equipment that isn't 'smart'?
Yes, with retrofit sensors sourced through a hardware partner or your existing vendor, we can bring legacy equipment's runtime and vibration data into the same monitoring platform as newer connected machinery.
What does an industrial IoT software project cost?
A monitoring dashboard for a single production line typically costs $8,000–$15,000. Full predictive maintenance platforms across multiple lines with historical modeling range $17,000–$27,000 depending on data sources and equipment count.
Industrial IoT Software for Manufacturers in USA, UAE & Saudi Arabia
WORKFLOX builds the predictive maintenance and equipment monitoring software layer for manufacturing and logistics operators across the GCC, US, and UK. We work with the sensors and PLCs you already run on the plant floor, we do not manufacture industrial hardware, and turn that data into dashboards and alerts your maintenance team can act on.
From Reactive Repairs to Data-Driven Maintenance Planning
Most plants we work with maintain equipment on a fixed calendar, regardless of actual condition. We build the data pipelines and dashboards that shift maintenance from calendar-based to condition-based, backed by real telemetry from your production lines rather than guesswork.
Industries We Serve
Industry-Specific Expertise
Next step
Scope Your Industrial IoT Solutions Project
Tell us what you are building and which systems it touches. We will reply with a recommended approach and a fixed-price proposal for your industrial iot solutions project, with no commitment.
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