Development of Low-Cost IIoT Solution for Smart Factories in MSME Industries: Utilizing Current Measurements for Machine and Factory Monitoring

Abstract

In response to an evolving industrial landscape, monitoring industrial assets and systems involves aggregating data from diverse sources within a production system to assess the performance of machinery, and associated processes. This paper is dedicated to the development of an affordable IIoT solution for productivity monitoring in MSME industries and also being implemented in the development cell for manufacturing setup. The devised solution leverages cost-effective hardware for sensing, a controller for data acquisition and analysis, and an edge gateway for cloud storage. The collected data are processed and analyzed through web-based front-end and back-end software technologies designed for machine and factory monitoring. The solution offers insights into factory and machine statuses, facilitates productivity tracking, and enables part count measurements. Furthermore, the software also provides users with automated reporting through Email and SMS, allowing for the creation of customized reports on a daily and monthly basis. Subsequently, the resulting experimental setup was successfully introduced as a low-cost solution to an industry, further validating its practicality and relevance in real-world settings. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.