Our client is a globally recognized manufacturer specializing in construction and agricultural equipment. The organization operates advanced manufacturing facilities and maintains stringent production quality standards to support both domestic and international markets.
As part of the AV Group, which has more than six decades of industrial legacy, they focus on precision manufacturing, operational excellence, and continuous digital transformation. Within the fabrication shop floor, manual and robotic welding processes play a critical role in ensuring structural strength, dimensional accuracy, and production throughput. However, welding operations faced several operational challenges due to the absence of structured digital monitoring.
What We Set Out to Achieve
Real-time monitoring of welding machine operational status — specifically arc running and idle conditions
Industrial IoT gateways connected to welding machines for automatic arc-state detection
Centralized dashboards enabling supervisors to monitor machine states across the shop floor
BEFORE M-CONNECT: WELDING MACHINE ARC-TIME AND UTILIZATION WERE ESTIMATED MANUALLY, NOT MEASURED
Pain Points Before Implementation
Welding operations faced several operational challenges due to the absence of structured digital monitoring.
Limited Real-Time Machine Visibility
Welding machine operations were largely tracked through manual logs and operator inputs, resulting in limited real-time visibility into machine operating conditions.
Inaccurate Machine Utilization Tracking
The absence of automated monitoring made it difficult to accurately measure actual arc running time and idle time across shifts.
Delayed Operational Insights
Production data collected through manual records often resulted in delayed and inconsistent information, making operational analysis and decision-making difficult.
How M-Connect Solved It
To address these challenges, Maestro Technology Services Pvt. Ltd. deployed the M-Connect Industrial IoT platform across the welding shop-floor environment. The solution was designed to enable real-time monitoring of welding machine operational status, specifically focusing on arc running and idle conditions. The solution was implemented with minimal disruption to production and integrated seamlessly into the existing shop-floor infrastructure.
Industrial IoT Gateways
Welding machines connected via industrial-grade IoT gateways — no machine modification required.
Arc-State Detection
Automatic detection of arc-on and arc-off events, providing accurate machine activity data.
Centralized Dashboard
Live operational status visible to supervisors and production teams across the facility.
M-CONNECT AUTOMATICALLY DETECTS ARC-ON AND ARC-OFF EVENTS — SHIFT BY SHIFT, MACHINE BY MACHINE
The M-Connect Technology Stack
Machine signals captured, processed, and presented as actionable shop-floor intelligence.
Industrial IoT Gateway Integration
M-Connect industrial IoT gateways were installed at each welding machine to capture electrical signals corresponding to machine operating states. This enabled automatic, continuous detection of arc-on and arc-off events without requiring manual operator input or machine modification.
Live Machine Activity Capture
Machine activity was monitored in real time, distinguishing between arc-running (productive) and idle states for each welding machine across every shift. This provided operational teams with an accurate picture of actual machine utilization vs. available production time — shift by shift, machine by machine.
Centralized Operational Dashboard
All machine-level data was aggregated into a centralized M-Connect dashboard accessible to supervisors and operational teams. The dashboard provided visibility into machine states across the welding shop floor, enabling supervisors to identify underperforming machines, excessive idle periods, and operational irregularities without physically walking the floor. Reports were available in shift-wise and daily formats, supporting structured operational review and continuous improvement.
What the Deployment Delivered
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Real-time visibility into welding machine arc-on and idle states
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Automated utilization tracking — eliminating manual estimation
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Shift-wise and daily reporting for operational review
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Centralized dashboards accessible to supervisors without floor walks
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A structured foundation for continuous welding productivity improvement
From Manual Observation to Digital Intelligence
The deployment of M-Connect across the welding shop floor replaced manual, inconsistent tracking with structured, automated machine monitoring — providing operational teams with the data needed to drive measurable improvements in welding machine utilization and shop-floor productivity.
"From manual observation to digital shop-floor intelligence — welding machine operations are now monitored in real time, shift by shift, machine by machine."