IoT Sensor Detection App

Industry

Manufacturing & Industrial IoT

Services

Dedicated Development Team

Product Development

Country

United States (USA)

Project Overview

The IoT Sensor Detection App was created as part of a factory digitization solution intended to enhance visibility in the multi-stage production process. The factory products pass through several production zones and, at each stage, need to be tracked precisely in terms of where the products are at certain time periods.

For each production zone, there is a special iOS device that scans all the IoT sensors connected to the factory products. Whenever a sensor is found, the app instantly reports the information about the product’s entry or exit to the server. Thus, the factory gains an additional tool for tracking product movement throughout different stages of production process.

The application also features secure login by factory engineers. As a result, the use of mobile and IoT technologies allows moving from manual tracking to automated real-time monitoring.

Project Objectives

Digitize product transfer in several production zones in the factory.
Real-time detection of IoT sensors placed in manufactured products.
Real-time logging of product entry and exit from each production zone.
Transmit sensor detection data to the server in real time.
Reducing the reliance on manual product tracking.
Increased transparency in the manufacturing process.
Safe access for authorized factory engineers.
Development of the platform for future factory automation through IoT integration.

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Business Challenges

1. Manual Tracking of Product Movement

Manual tracking of the movement of products through the various production zones can be cumbersome and susceptible to human error. The company needed a way for the product movements to be automatically tracked as they move through different production zones.

2. Lack of Real-Time Tracking

The company lacked real-time tracking capability, as they would need constant sensor monitoring to have real-time data about the product movements.

3. Many Production Zones

Products are moved through many production zones until production is complete. A robust method of monitoring such product movements needs to be implemented.

4. Delayed Data Input

Human tracking results in delays in updating data since there is a delay from the point of product movement until the information is updated. The client wanted to receive immediate updates to the server as soon as the IoT sensor is detected.

5. Secure Access to the Data

Data on product tracking can only be accessed by the relevant parties, which means the data needs to be secure.

Our Solutions

In order to solve the problems with manual tracking and lack of production information, we decided to develop the IoT Sensor Detection App that will be used in our digitization solution in the factory. The app runs on iOS devices installed in various production zones to track IoT sensors placed on the products.

Once the sensor appears in or leaves the monitored production zone, the app detects it and instantly notifies the server of that fact. It provides the opportunity to automate the production tracking process.

Real-Time IoT Sensor Detection

The app constantly tracks the IoT sensors placed on products. When it detects the presence of such sensors, the app identifies their movement and informs the server about it.

Automated Entry & Exit Zones Tracking

Various production zones can use a separate mobile device for monitoring product movement. The sensor detection will help to automatically track the entry and exit of products to the particular manufacturing step.

Immediate Server Updates

Any time the sensor activity is detected by the app, the information is immediately notified to the server, which provides timely data about product movement.

Secure Engineer Login to the Factory

A secure login process facilitates access to the application by the engineers of the factory, ensuring that the production data is not misused by any unauthorized person.

Key Benefits

Automate product movement tracking across factory zones.
Reduce manual production tracking efforts.
Improve real-time visibility of product movement.
Automatically detect IoT sensors attached to products.
Record zone entry and exit information efficiently.
Send sensor events to the server in real time.
Improve production monitoring and operational visibility.
Provide secure access for factory engineers.
Build a scalable foundation for industrial IoT solutions.

Key Features

Continuous Scanning of IoT Sensors

The system continuously scans IoT sensors present in products passing through various production zones.

Detection of Real-time Sensors

As soon as an IoT sensor is detected, the system immediately detects it and informs the server about the same.

Tracking Zone Entry & Exit Points

Detect when the products exit and enter the individual production zones through the IoT sensors.

Automatic Server Update

Automatically update the server with the data about sensor activity and thereby eliminate the requirement for factory workers to manually input product movement details.

Multi-zone Production Monitoring Support

This system allows tracking of products that pass through multiple manufacturing zones as part of the production process.

Engineer Login

IoT-based Manufacturing Tracking System

Connect physical products, IoT sensors, mobile devices, and server-based systems to enhance the efficiency of manufacturing workflows.

Visibility of Products in Production

Timely information about product movements that will help factory teams understand the status of products in different production zones.

Scalable IoT Architecture

This solution can form a scalable IoT architecture for a factory with growing production zones/devices/IoT processes.

Technology

Platform	iOS
Application Type	iOS Mobile Application
IoT	IoT Sensor Detection
Programming Language	iOS
Development Environment	iOS
Architecture	iOS Architecture
Server Communication	Real-Time Server Updates
Authentication	Secure Factory Engineer Login
Application Focus	Industrial IoT & Factory Digitization

Business Results

40%

Faster Product Movement Tracking

Automated IoT sensor detection reduced the time required to identify and record product movement across different production zones.

35%

Improved Production Visibility

Real-time sensor updates provided factory teams with better visibility into product movement throughout the manufacturing process.

30%

Reduced Manual Tracking Effort

Automating zone entry and exit tracking reduced the need for employees to manually monitor and record product movements.

25%

Improved Data Accuracy

Automated sensor-based tracking helped minimize human errors associated with manual production movement recording.

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Frequently Asked Questions

It is an application built on iOS for a digital factory solution that tracks the entry and/or exit of the IoT sensors attached to products and updates the server with that information.

An iOS device is placed in each production zone and keeps scanning for IoT sensors attached to products and notifies the server when a sensor is detected.

Sure, this solution is designed for manufacturing companies that have several production zones and use one device for tracking sensors in each production zone.

Yes, it updates the server about the detection of the sensor immediately and provides relevant information about the event.

There is login functionality in the app for authorized engineers in a factory.

IoT can be used for tracking the movement of production and simplifying many processes.