AI-Enabled Industrial IoT Solutions: Turn Factory Data into Your Competitive Edge
Stop reacting to downtime. Start predicting it. We engineer intelligent IIoT systems that connect your machines, analyze real-time data, and unlock unprecedented operational efficiency.
Start Your IIoT Journey
From Reactive Repairs to Predictive Profits
In today's market, manufacturing leaders can no longer afford to fly blind. Traditional reactive maintenance is a losing game. It's time to evolve.
The Old Way: The High Cost of 'If It Ain't Broke'
Operating without real-time data is like driving at night with the headlights off. You're vulnerable to sudden failures that bring production to a grinding halt.
- Unplanned downtime bleeds profits and damages reputation.
- Quality issues discovered too late lead to scrap and rework.
- Inefficient processes and energy waste inflate operational costs.
- Data silos between the factory floor (OT) and business systems (IT) prevent smart decisions.
The New Way: AI-Enabled IIoT Intelligence
We transform your factory into a smart, interconnected ecosystem where data-driven decisions become your most powerful asset.
- Predict equipment failures before they happen with AI-powered analytics.
- Gain 24/7 visibility into every machine, line, and process.
- Optimize asset performance and energy consumption in real-time.
- Securely unify OT and IT data to unlock holistic business insights.
Our End-to-End Industrial IoT Services
We provide a comprehensive suite of services to guide you at every stage of your smart factory transformation, from initial strategy to ongoing optimization.
IIoT Strategy & Consulting
We align IIoT initiatives with your core business objectives, creating a practical, phased roadmap that guarantees measurable ROI and avoids costly missteps.
- Identify high-impact use cases for rapid value demonstration.
- Develop a scalable architecture blueprint for long-term growth.
- Conduct ROI analysis and build a compelling business case.
Sensor Integration & Legacy Asset Retrofitting
Unlock data from your most valuable assets, old or new. We specialize in outfitting legacy machinery with modern sensors and gateways for seamless data acquisition.
- Select the right sensors (vibration, thermal, pressure, etc.) for your needs.
- Implement non-invasive retrofitting to minimize operational disruption.
- Ensure reliable data flow from machine to network.
OT/IT Systems Integration
We securely bridge the critical gap between your operational technology (PLCs, SCADA, MES) and your enterprise IT systems (ERP, CRM), creating a single source of truth.
- Develop secure data pipelines between the factory floor and the cloud.
- Synchronize production data with inventory, finance, and supply chain systems.
- Break down data silos to enable end-to-end process visibility.
Edge Computing & Data Processing
Process data right at the source for real-time decision-making. Our edge solutions reduce latency, minimize data transfer costs, and enable immediate automated responses.
- Deploy edge gateways for on-site data filtering and aggregation.
- Run machine learning models directly on the edge for instant anomaly detection.
- Ensure continuous operation even with intermittent network connectivity.
IIoT Security & Compliance
Security is not an afterthought; it's our foundation. We implement a multi-layered, Zero Trust security architecture to protect your critical operational data and infrastructure.
- Secure devices, networks, and cloud platforms from cyber threats.
- Ensure compliance with industry-specific regulations (e.g., ISA/IEC 62443).
- Implement robust identity and access management for all IIoT components.
Predictive Maintenance (PdM) Solutions
Move from reactive repairs to proactive optimization. Our AI models analyze sensor data to predict equipment failures, allowing you to schedule maintenance precisely when needed.
- Reduce unplanned downtime by up to 50%.
- Extend asset lifespan and optimize maintenance schedules.
- Lower maintenance costs by eliminating unnecessary preventative tasks.
AI & Machine Learning Model Development
Go beyond simple dashboards. We build, train, and deploy custom machine learning models that uncover hidden patterns, predict outcomes, and prescribe optimal actions.
- Develop models for anomaly detection, root cause analysis, and yield optimization.
- Utilize techniques like deep learning for complex pattern recognition.
- Implement MLOps for continuous model monitoring and improvement.
Custom IIoT Platform Development
When off-the-shelf solutions don't fit, we build a tailored IIoT platform on leading cloud services (AWS, Azure, GCP) that perfectly matches your unique operational needs.
- Create intuitive dashboards for real-time Overall Equipment Effectiveness (OEE).
- Build a scalable data lake for historical analysis and trend discovery.
- Develop custom APIs for integration with other business applications.
Cloud Data Engineering & Analytics
We build the robust cloud foundation your IIoT data deserves. Our experts design and manage high-performance data pipelines, data lakes, and analytics warehouses.
- Leverage services like AWS IoT Core, Azure IoT Hub, and Google Cloud IoT.
- Implement scalable data storage and processing solutions.
- Create powerful BI dashboards for C-suite and operational reporting.
Digital Twin Implementation
Create a living virtual replica of your physical assets and processes. Digital twins enable advanced simulation, what-if analysis, and process optimization in a risk-free environment.
- Simulate the impact of process changes before implementation.
- Visualize complex operations and data flows in an interactive 3D model.
- Accelerate operator training and remote diagnostics.
Quality Control with AI-Powered Machine Vision
Automate and enhance quality inspections with superhuman accuracy. Our machine vision solutions use AI to detect microscopic defects, verify assemblies, and ensure 100% quality compliance.
- Reduce scrap rates and prevent defective products from reaching customers.
- Increase inspection speed and consistency over manual methods.
- Capture and analyze image data for root cause analysis of quality issues.
Real-Time Asset Tracking & Monitoring
Gain complete visibility over your high-value assets, tools, and work-in-progress (WIP) across the entire facility. Know where everything is, all the time.
- Optimize asset utilization and prevent loss or theft.
- Automate inventory tracking and reduce manual cycle counts.
- Improve production flow by locating materials and tools instantly.
Supply Chain & Logistics Visibility
Extend the power of IoT beyond your factory walls. Monitor your supply chain in real-time to track shipments, monitor environmental conditions, and predict delivery times.
- Improve logistics efficiency and reduce transportation costs.
- Ensure the integrity of sensitive goods with condition monitoring.
- Provide customers with accurate, real-time tracking information.
Energy Management & Optimization
Identify and eliminate energy waste to reduce costs and improve sustainability. Our IIoT solutions monitor consumption at the machine level, revealing opportunities for significant savings.
- Lower utility bills and reduce your carbon footprint.
- Correlate energy usage with production schedules to optimize efficiency.
- Support ESG (Environmental, Social, and Governance) reporting initiatives.
Managed IIoT Services & 24/7 Support
Focus on your core business while we manage your IIoT ecosystem. We provide ongoing monitoring, maintenance, and optimization to ensure peak performance and continuous value.
- Proactive system health monitoring and performance tuning.
- 24/7 support for critical issue resolution.
- Continuous improvement of AI models and analytics dashboards.
Why Partner with CIS for Your IIoT Transformation?
We're not just technologists; we're manufacturing transformation partners. Our unique blend of deep engineering expertise, AI prowess, and business acumen sets us apart.
Full-Stack IIoT Expertise
From silicon to cloud, we manage the entire IIoT stack. Our teams include hardware engineers, embedded systems developers, cloud architects, and data scientists, providing a single, accountable partner for your entire project.
Legacy & Brownfield Specialists
Your factory's age isn't a barrier. We excel at retrofitting existing machinery and integrating disparate legacy systems (OT/IT), unlocking data from your most critical assets without requiring a complete overhaul.
Enterprise-Grade Security First
With CMMI Level 5, SOC 2, and ISO 27001 certifications, we build security into the DNA of your IIoT solution, protecting your operational technology and sensitive production data from the ground up.
Proven ROI and Business Outcomes
We focus on tangible results that matter to your bottom line: increased OEE, reduced downtime, lower maintenance costs, and improved quality. Our solutions are designed to deliver a clear and compelling return on investment.
Scalable, Future-Proof Architecture
We don't build dead-end pilots. Our solutions are architected on leading cloud platforms for enterprise-wide scalability, ensuring your IIoT system can grow and evolve with your business needs.
Dedicated AI-Enabled POD Model
You get more than just developers. You get a dedicated, cross-functional Product-Oriented Delivery (POD) team—a self-contained unit of strategists, engineers, and data scientists focused solely on your success.
20+ Years of Engineering Excellence
Since 2003, we've been solving complex engineering challenges for global enterprises. We bring decades of experience in software development, system integration, and project management to every IIoT engagement.
AI-Augmented Delivery
We leverage enterprise-grade AI tools within our own development lifecycle. This means faster implementation, higher code quality, and more innovative solutions for you, governed by our strict data privacy and security framework.
Flexible Engagement Models
From strategic consulting and pilot projects to full-scale implementation and managed services, we offer flexible engagement models that align with your budget, timeline, and strategic objectives.
Our Proven 4-Step IIoT Implementation Roadmap
We follow a structured, collaborative process to de-risk your investment and accelerate time-to-value, ensuring your IIoT solution is a success from pilot to enterprise-wide deployment.
Discover & Strategize
We start by understanding your business goals. Our experts collaborate with your team in workshops to identify high-impact use cases, assess your current infrastructure, and build a data-driven business case and strategic roadmap.
Design & Architect
Our solution architects design a scalable and secure IIoT blueprint. This includes selecting the right sensors and hardware, designing the data pipeline, and defining the cloud architecture and analytics models tailored to your specific needs.
Deploy & Integrate
Our agile development teams get to work. We deploy sensors, configure gateways, build the cloud platform, and integrate with your existing OT/IT systems. We focus on a pilot deployment to a specific line or area to demonstrate value quickly.
Optimize & Scale
Once the pilot proves successful, we scale the solution across your enterprise. We continuously monitor performance, refine AI models with new data, and provide ongoing support to ensure you maximize the long-term value of your IIoT investment.
Real-World Results: Our IIoT Success Stories
We deliver measurable improvements in efficiency, uptime, and quality. Explore how we've helped manufacturing leaders like you turn data into a strategic asset.
Automotive Parts Manufacturer
Industry: Automotive
Client Overview: A Tier 1 supplier for major automotive OEMs, operating multiple high-volume production facilities. They faced intense pressure to maintain delivery schedules and quality standards, but were hampered by frequent, unpredictable failures of their critical stamping presses.
"CIS didn't just sell us technology; they solved our biggest production headache. The ability to see a failure coming days in advance has completely changed how we manage our maintenance and production planning."
- Michael Harper, Director of OperationsThe Challenge: Crippling Downtime from Stamping Press Failures
The client's primary challenge was the reactive nature of their maintenance. A single press failure could halt an entire production line, causing costly delays, missed deadlines, and significant overtime expenses for emergency repairs.
- Frequent, unpredictable equipment breakdowns.
- High costs associated with emergency repairs and scrap parts.
- Inability to accurately forecast maintenance needs.
- Lack of data to identify the root causes of recurring failures.
Our Solution: An AI-Powered Predictive Maintenance Platform
CIS designed and implemented an end-to-end predictive maintenance solution focused on the client's most critical assets.
- Retrofitted stamping presses with advanced vibration and thermal sensors.
- Deployed edge gateways to pre-process data on the factory floor.
- Built a custom data pipeline to stream sensor data to Microsoft Azure.
- Developed and trained a machine learning model in Azure ML to predict failures based on subtle changes in sensor readings.
Global CPG Company
Industry: Consumer Packaged Goods
Client Overview: A multinational CPG company with a complex, high-speed packaging operation. While they knew their lines weren't running at peak efficiency, they lacked the real-time data to pinpoint the exact causes of slowdowns, micro-stoppages, and quality deviations.
"The real-time OEE dashboard has become the single source of truth for our production floor. We're no longer guessing where the problems are; we're making data-backed improvements every single shift."
- Olivia Bishop, Plant ManagerThe Challenge: Uncovering the "Hidden Factory" of Inefficiency
The client's goal was to increase throughput without significant capital investment. They needed to understand the true drivers of their Overall Equipment Effectiveness (OEE) score to identify and eliminate bottlenecks.
- Lack of real-time visibility into line performance.
- Difficulty in identifying the root cause of frequent micro-stoppages.
- Manual and often inaccurate data collection processes.
- Inability to benchmark performance across different shifts and lines.
Our Solution: Real-Time OEE Monitoring and Analytics
We implemented a comprehensive IIoT solution to automatically capture and analyze production data from their primary packaging line.
- Installed a network of sensors to track machine status, cycle times, and output counts.
- Integrated with existing PLCs to capture fault codes and operational parameters.
- Developed a centralized, cloud-based platform to calculate and visualize OEE (Availability, Performance, Quality) in real-time.
- Created intuitive dashboards for operators, supervisors, and managers with role-specific KPIs.
Specialty Chemical Plant
Industry: Chemical Manufacturing
Client Overview: A producer of specialty chemicals with highly sensitive manufacturing processes. Maintaining precise temperature, pressure, and environmental conditions was critical for both product quality and regulatory compliance, a process that relied heavily on manual checks and paper logs.
"CIS has transformed our compliance and safety procedures. The automated monitoring and alerting system gives us peace of mind and has freed up our expert technicians to focus on process improvement instead of manual data logging."
- Henry Coleman, Compliance & Safety OfficerThe Challenge: Ensuring Safety and Automating Compliance
The client needed to modernize their monitoring system to prevent costly process deviations and simplify their burdensome compliance reporting. The risk of human error in manual logging was a significant concern.
- Risk of process deviations leading to batch spoilage.
- Heavy reliance on manual, error-prone data collection.
- Time-consuming process for generating compliance reports for audits.
- Delayed response to critical environmental condition changes.
Our Solution: Automated Condition Monitoring & Reporting
We deployed a robust network of industrial-grade sensors to provide 24/7 monitoring of all critical process parameters.
- Installed certified sensors for temperature, humidity, and pressure in key production and storage areas.
- Configured a centralized system with real-time dashboards and trend analysis.
- Implemented an automated alerting system that sends SMS and email notifications when parameters approach predefined thresholds.
- Developed a feature to automatically generate historical compliance reports in an audit-ready format.
Our Technology Ecosystem
We are technology-agnostic and leverage a best-in-class ecosystem of hardware, platforms, and tools to build the optimal IIoT solution for your specific environment.
AWS IoT
Azure IoT Hub
Google Cloud IoT
AI/ML Development
Containerization
Orchestration
IoT Protocols
Dashboards
IaC
Edge Devices
PLC/SCADA
ML Frameworks
What Our Clients Say
"The predictive maintenance solution from CIS has been a game-changer. We've cut our unplanned downtime by nearly half and can now schedule repairs with surgical precision. Their team understood our operational challenges from day one."
"We always knew we could be more efficient, but CIS gave us the data to prove it. The real-time OEE dashboards are now central to our daily production meetings. Their ability to integrate with our legacy PLCs was impressive."
"For us, IIoT was about safety and compliance first. The automated monitoring and alerting system CIS built has given us unparalleled peace of mind and significantly reduced the burden of audit preparation."
"The CIS team's expertise in both OT and IT was the key differentiator. They spoke the language of our control engineers and our cloud architects, successfully bridging a gap that had been a major challenge for us for years."
"We started with a small pilot project on a single line. The results were so compelling that we had the business case to scale across the entire facility within six months. CIS's phased approach made the investment manageable and proved the value every step of the way."
"Data security was our biggest hurdle to adopting cloud-based IIoT. CIS's deep knowledge of cybersecurity and their transparent, security-first design process gave our leadership team the confidence to move forward."
Meet Our IIoT Practice Leaders
Your project will be guided by seasoned experts with deep, cross-functional experience in manufacturing, cloud architecture, data science, and cybersecurity.
Akeel Q.
Manager, Certified Cloud Solutions & AI/ML Specialist
Prachi D.
Manager, Certified Cloud & IoT Solutions Expert
Vishal N.
Manager, Senior Data Scientist (AI/ML)
Joseph A.
Expert, Cybersecurity & Software Engineering
Frequently Asked Questions
Industrial IoT (IIoT) refers to the network of sensors, instruments, and other devices connected to industrial applications, including manufacturing and energy management. Unlike consumer IoT (like smart home devices), IIoT is focused on instrumentation and control in high-stakes environments. It prioritizes reliability, precision, and security to optimize operational processes, predict failures, and improve safety in settings like factories, power plants, and refineries.
Absolutely. This is one of our core areas of expertise. We specialize in "brownfield" deployments, which involve retrofitting legacy equipment with modern, non-invasive sensors and gateways. We can extract data from older PLCs or add new sensing capabilities to analog machines, bringing them into your smart factory ecosystem without requiring costly replacements.
Security is our highest priority. We implement a defense-in-depth strategy that includes: 1) Device-level security with encrypted communications. 2) Network segmentation to isolate OT from IT systems. 3) Secure cloud architecture following best practices from AWS/Azure/GCP. 4) Robust identity and access management. Our processes are backed by our SOC 2 and ISO 27001 certifications, ensuring your data is protected at every layer.
While ROI varies by application, it's typically driven by a few key areas. For predictive maintenance, clients often see a 25-30% reduction in maintenance costs and a 35-45% reduction in unplanned downtime. For OEE optimization, a 15-20% improvement is common. We work with you during the initial strategy phase to build a detailed business case with a clear ROI projection based on your specific operational data and goals.
We advocate for a phased approach to deliver value quickly. A typical pilot project, focused on a single production line or a specific set of critical assets, can often be completed in 12-16 weeks. This allows you to see tangible results and build momentum for a broader, enterprise-wide rollout, which is planned in subsequent phases based on the initial project's success.
No, you don't. Our service can be end-to-end. We provide the data scientists and AI/ML experts who build, train, and maintain the predictive models. We deliver the output as clear, actionable insights through intuitive dashboards and automated alerts. We can also work collaboratively to upskill your existing team if you wish to build in-house capabilities over time.
Ready to Build Your Smart Factory?
Let's talk about your operational challenges and build a roadmap to transform your factory floor. Schedule a free, no-obligation consultation with our IIoT experts today.