How IoT integration and custom software have changed monitoring in the metalworking industry

For metalworking companies aiming to digitalize machines and production lines, the integration of IoT technologies, industrial communication protocols, and custom software platforms is a strategic step. The objective is to build an interoperable infrastructure capable of connecting machines, plants, and IT systems through protocols such as Modbus TCP, OPC UA, and Profinet, enabling real-time monitoring and secure remote access.

Through this integration, companies can:

• acquire energy consumption and process data directly from field devices;
• centralize production data across machines, lines, and departments;
• convert raw data into KPIs for efficiency analysis and performance optimization;
• enable predictive maintenance strategies and advanced operational cost control.

Within this industrial IoT and software integration framework, specialized companies such as BriaSOFT support metalworking businesses in developing integrated solutions that combine industrial IoT and custom software, transforming monitoring from a simple data collection activity into a concrete operational management tool.

The following section outlines how this approach can be implemented in a real production environment.

Case study: monitoring a spring manufacturing plant

In a spring manufacturing plant, BriaSOFT integrated its monitoring system with the production line through an automated part counter, enabling continuous control of output.

At predefined intervals, the BriaSOFT system prompts the machine to perform an automatic dimensional check of the produced spring. The measured value is then compared with the specifications set in the platform:

• if the measurement complies with the defined specifications, production continues without interruption;
• if the deviation falls within a pre-defined tolerance range, a notification is sent through the internal messaging system, highlighting a potential process drift;
• if the part is outside the tolerances, the plant is automatically stopped and an alarm is triggered.

This approach allows operators to intervene immediately in the event of dimensional deviations, reducing the risk of nonconforming production and reinforcing in-process quality control directly at machine level.

Crono MES system and integrated maintenance management

The Crono MES system developed by BriaSOFT integrates with industrial plants and collects real-time production progress data. By correlating machine status, cycle times, and orders it is possible to get a clear view of the actual productivity of work centers and compare planned versus actual performance.

In parallel, the integrated maintenance module allows companies to schedule preventive activities, record corrective interventions, and associate maintenance events with historical downtime data. This creates the foundation for a structured approach to preventive maintenance and accurate control of operational costs.

From raw data to measurable OEE performances

Once acquired, the data are correlated with orders, work centers, and shifts, ensuring the OEE calculation is therefore based on actual machine states, rather than estimates. This approach enables detailed analysis of downtime causes, recurring micro-stoppages, and deviations from theoretical cycle times.

Operational dashboards and historical reports allow the identification of bottlenecks, the evaluation of work center utilization, and more accurate planning of corrective actions.

To learn more about BriaSOFT solutions, you can visit the online stand on Expometals or request a dedicated technical consultation.