Replaced Manual Monitoring with Real-Time IoT Visibility for Mid-Sized Logistics Company
About Client
The client is a mid-sized cold chain logistics company that operates across Western Europe and the United Kingdom. The company mainly deals in temperature-controlled warehousing and last-mile distribution for pharmaceutical and food clients.
The perishable inventory worth millions moving thousands of miles every day made temperature and humidity control technology a contractual obligation. As the business evolved, the manual management of equipment health became unsustainable while the costs kept climbing.
Key Challenges
In the absence of a unified system that tracks equipment status, facility managers mainly relied on manual inspection, which caused errors and latency. Each facility required 3-4 inspection sessions per day, across 14 occasions, resulting in over 200 combined man-hours.
Reactive maintenance often led to high cost, as the average time between fault onset and detection was more than 4 hours. By the time facility managers were informed about the fault, the damage had often begun. Also, operations leadership had no central view of equipment health. Thus, each facility produced their sperate reports in different formats, further challenging maintenance planning.
Our Solutions
Our team built a real-time IoT monitoring platform that offers consistent visibility across 14 facilities on a single interface.
Centralized Dashboard
We deployed a facility-agnostic dashboard to offer real- time reading of all the connected assets. It offers color-coded alerts, assigns tasks to responsible technicians, and brings visibility into historic trends for better maintenance planning.
IoT Sensor Network
An end-to-end network of humidity and temperature sensors, along with vibration devices, was integrated with existing refrigeration units and HVAC systems. Sensor data updates every 30 seconds, reducing latency and pushing information to the central system.
Predictive Maintenance Engine
The IoT platform consisted of an AI-powered predictive maintenance engine that proactively monitors the equipment performance to identify the chances of failure and alert the relevant technician before a major loss occurs.
Impact That Drives Results
The platform had changed the fundamental way of how client operation team works within 6 months of deployment. Manual inspections are now only required for exception handling.
91%
Reduced Manual Monitoring Hours
The IoT platform consistently tracks equipment and collects the required data, enabling facility managers and the human workforce to focus more on actual maintenance work.
78%
Reduced Downtime
The predictive maintenance system identifies the failure pattern in 23 different instances, resulting in a significant reduction of downtime and unplanned shutdowns.
95.42%
Incident Response Time Reduced from 4 Hours to 11 Minutes
The automatic technician assignment replaced the manual discovery during inspection rounds, fostering real-time response.
$420,000
Annual Maintenance Cost Saving
The IoT ecosystem reduces repair callouts, spoilage losses, and labor costs, driving measurable financial impact within the first year.
