Connect the Factory Floor to the Cloud
SkySync helps manufacturers across automotive, FMCG, chemicals, and heavy industry build IoT-enabled smart factories, AI-powered quality systems, and real-time supply chain visibility platforms.
What Keeps Your CTO Up at Night
Unplanned Downtime
Reactive maintenance strategies leading to costly production stoppages and missed delivery commitments.
Quality Defects
Manual quality inspection processes that miss defects, generate rework, and increase scrap rates.
Supply Chain Blind Spots
Lack of real-time visibility across multi-tier supplier networks, leading to stockouts, delays, and excess inventory.
OT/IT Integration
Operational technology (PLCs, SCADA, MES) and IT systems running in silos, preventing data-driven decision-making on the shop floor.
How SkySync Helps
Predictive Maintenance Platform
IoT sensor data ingestion and ML models that predict equipment failures 2–4 weeks in advance, reducing unplanned downtime by up to 35%.
AI-Powered Quality Inspection
Computer vision systems for automated defect detection on production lines — faster, more consistent, and more accurate than manual inspection.
Smart Factory IoT Platform
End-to-end IoT architecture connecting PLCs, SCADA, and MES to a cloud data platform — enabling real-time OEE monitoring and digital twin capabilities.
Supply Chain Visibility
Real-time tracking and analytics across multi-tier supplier networks, with AI-powered demand forecasting and inventory optimisation.
Digital Twin
High-fidelity digital replicas of production lines and assets, enabling simulation, optimisation, and remote monitoring without physical access.
Energy & Sustainability Analytics
Real-time energy consumption monitoring and AI-driven optimisation to reduce carbon footprint and meet ESG reporting requirements.
Results That Speak for Themselves
Client
Top-5 Indian Automotive Components Manufacturer
The Challenge
Unplanned downtime costing ₹2.5 Cr per month across 8 plants, with no visibility into equipment health and a reactive maintenance model that couldn't scale.
Our Solution
SkySync deployed an IoT-based predictive maintenance platform on AWS IoT Core, connecting 1,200 sensors across 8 plants to an ML pipeline that predicts failures 3 weeks in advance.
Outcomes
- Unplanned downtime reduced by 38% within 6 months
- Monthly downtime cost reduced from ₹2.5 Cr to ₹1.1 Cr
- OEE improved from 71% to 84% across all plants
- Maintenance team productivity increased by 45%
- Full ROI achieved in 11 months
Ready to build your smart factory?
Talk to our Industry 4.0 specialists about your IoT, AI, and cloud modernisation goals.