The Challenge

Titan Manufacturing operated multiple heavy-machinery facilities with legacy equipment that lacked modern diagnostic capabilities. Unplanned machine failures were costing them millions annually in halted production lines. They needed a scalable way to retrofit existing machinery with IoT sensors and a centralized platform for real-time monitoring.

Our Solution

Chirp Tech designed an end-to-end industrial IoT architecture combining edge gateways, AWS IoT Core, and machine learning-based anomaly detection.

• Real-Time Telemetry Ingestion:High-throughput MQTT pipelines handling 50,000+ data points per second with sub-second latency.
• Predictive AI Maintenance:Machine learning models predicting failures up to 14 days in advance using vibration and temperature trends.
• Digital Twin Command Center:3D factory dashboard enabling real-time monitoring and instant equipment diagnostics.

The Results

ForgeSense paid for itself within three months, shifting the factory from reactive maintenance to predictive operations.