"From Legacy to Legendary: How a Smart Factory Got Smarter with Wavefuel"

🚨 The Challenge

• Multiple factory units with aging PLCs, Modbus and OPC-UA-based equipment
• No unified view of machine status or energy consumption
• High unplanned downtime due to delayed maintenance and lack of real-time alerts
• Teams relied on paper-based logs and manual fault checks
• Data was siloed—no way to extract insights across machines or locations

💡 The Wavefuel Solution

✅ 1. Unified Connectivity

Wavefuel’s device-agnostic platform connected 200+ machines using Modbus, OPC-UA, and MQTT—without any hardware replacement.

✅ 2. Live Operational Dashboards

Using Halo, the factory team created real-time dashboards to monitor key parameters: temperature, vibration, motor status, energy usage, and cycle times.

✅ 3. Predictive Maintenance with Rules

The Rule Engine was used to trigger alerts when motor vibration exceeded safe thresholds or when temperature spiked—preventing breakdowns before they occurred.

✅ 4. Mobile Monitoring

The factory floor operators used a custom screens (built using Wavefuel’s SDK) to track machine health and get notified instantly.

✅ 5. AI Assistant for Maintenance

Lighthouse AI allowed managers to simply “chat” with the system—e.g., “Show me machines nearing overheating in Plant 2.”

📈 The Result

• 🔻 30% reduction in unexpected downtime within the first 90 days
• ⚙️ 25% faster response time to on-floor issues
• 💰 Saved $110K annually on maintenance labor and emergency part replacement
• 🧠 Increased operator awareness with mobile alerts and dashboards
• 🌐 Scaled to 4 additional units with zero additional dev work—just plug and monitor

🧠 Key Features Used

1. Lighthouse Platform
2. Rule Engine
3. Dashboard Builder
4. SDK for Custom App
5. Multi-Protocol Support (OPC-UA, Modbus, MQTT)