OVERVIEW
A leading Italian industrial jack manufacturer operating in the global manufacturing market needed a scalable remote monitoring solution to enhance post-sales service and equipment reliability. Mipu deployed an integrated IoT monitoring system combining edge gateways and a cloud-based platform, enabling real-time visibility of all installed industrial equipment worldwide. This solution empowers Maintenance Managers and Operations Leaders with autonomous monitoring capabilities, from first activation through daily operations, supporting productivity optimization and proactive maintenance.
INITIAL SITUATION
The client is a Milan-area manufacturing company founded over 30 years ago, currently operating from a 20,000 m² production facility. Its competitive advantage lies in nearly complete vertical integration, enabling the design and production of highly customized and reliable industrial jacks. These systems are used for lifting, pulling, moving, and aligning loads with perfect synchronization across a wide range of industrial applications.
As IoT adoption accelerated within the manufacturing industry, the company identified an opportunity to differentiate its post-sales service through remote equipment monitoring. However, the existing approach offered limited visibility into equipment performance once installed at customer sites. Without real-time operational data, Maintenance Managers could not proactively plan maintenance activities, while Operations Leaders lacked insights to optimize productivity and improve reliability across installed assets.
To remain competitive, the manufacturer required a unified monitoring platform capable of tracking industrial jack performance worldwide and providing independent access to operational data for both internal teams and end customers.
THE CHALLENGE
The main challenge was to achieve global visibility of installed industrial jack systems through a scalable IoT platform that could:
- Collect real-time operational data from distributed manufacturing equipment across multiple customer sites
- Aggregate data from individual units while enabling site-based grouping by customer
- Monitor critical performance parameters such as activations, temperature trends, alarms, rotation counts, and distance traveled
- Provide autonomous access for end customers, from commissioning to ongoing performance analysis
- Support highly customized industrial products without compromising data integrity or system scalability
The technical complexity involved connecting field equipment to a centralized monitoring platform while ensuring reliable data transmission across diverse industrial environments and operational conditions.
THE SOLUTION
Mipu delivered a robust IoT architecture designed specifically for industrial manufacturing environments, combining edge computing and cloud analytics:
Hardware Deployment:
The Davide edge gateway was installed near each industrial jack. This device captures real-time operational data directly from the equipment and securely transmits it to the cloud platform with minimal latency, ensuring reliable monitoring for Maintenance Managers.
Cloud Platform Integration:
All data is collected and processed within Rebecca, Mipu’s cloud-based IoT monitoring platform. The main dashboard provides immediate visibility of all installed jacks across the global customer base, supporting centralized asset management.
Site Organization:
Equipment is logically grouped by customer and location, allowing Operations Leaders and end customers to monitor all jacks installed at a specific site through consolidated dashboards.
Data Experience Development:
Custom analytics modules were developed to monitor jack-specific KPIs. These Data Experiences track activation cycles, temperature evolution, alarm events, rotation metrics, and linear distance traveled, enabling data-driven decisions to improve reliability and optimize productivity.
Customer Enablement:
The platform was designed for autonomous use, allowing end customers to access performance data and generate reports with minimal training, reducing dependency on manufacturer support teams.
RESULTS
The implemented remote monitoring solution delivered a unified industrial IoT ecosystem with tangible benefits for manufacturing operations:
- Centralized Visibility:
The manufacturer now manages all installed industrial jacks worldwide through a single monitoring platform, eliminating fragmented data sources and manual reporting. - Customer Autonomy:
End customers independently access equipment data from commissioning onward, enabling proactive maintenance strategies and reducing support requests. - Comprehensive Analytics:
Automated tracking of key performance indicators provides actionable insights into equipment utilization, thermal behavior, and operational anomalies, supporting predictive maintenance and improved reliability. - Scalable Architecture:
The solution supports business growth and new installations without requiring platform reconfiguration, ensuring long-term scalability for the manufacturing environment. - Enhanced Post-Sales Service:
Post-sales service evolved from reactive support to proactive equipment management, strengthening customer relationships and creating opportunities for continuous product and process optimization.
Integrated reporting tools allow both internal teams and customers to document equipment performance for compliance, maintenance planning, and ongoing productivity optimization within their manufacturing operations.
