Industrial IoT & Machine Telemetry Pipeline
End-to-end IoT monitoring pipeline streaming real-time machine telemetry from ESP32 microcontrollers and Modbus PLC networks to desktop and web dashboards.
1. Context & Problem Statement
An industrial telemetry acquisition system at PT Samjin Indonesia designed to capture operational metrics, cycle counts, power status, and error states directly from factory machines, replacing manual paper logs with automated real-time dashboards.
2. System Architecture & Workflow
[Assembly Machines / PLCs]
│ (Modbus RS485)
▼
[ESP32 Edge Microcontrollers]
│ (MQTT / Wi-Fi & Ethernet)
▼
[Central Telemetry Server]
├─ Real-Time WebSocket Broadcaster
├─ Time-Series Aggregator (PostgreSQL)
└─ Anomaly Rule Engine
│
┌───────┴───────┐
▼ ▼
[Supervisor Web Dashboard] [Desktop Floor Display]
3. Technical Highlights & Automation
• Sensor Ingestion: ESP32 continuously polls PLC Modbus holding registers. • Event Detection: When a machine status changes (Running -> Idle -> Error), payload is published to MQTT broker. • Alerting: If idle state exceeds 3 minutes without operator code, notifications are triggered to line leaders.
4. Measurable Results & Impact
Delivered actionable OEE (Overall Equipment Effectiveness) visibility, empowering management to optimize cycle bottlenecks and schedule preventive maintenance effectively.
Engineering Retrospective
Edge microcontrollers in manufacturing must be treated with the same fault-tolerant considerations as enterprise servers, including local buffering and hardware watchdogs.
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