The Real-Time Manufacturing Intelligence Platform
IoTFlows is a manufacturing intelligence platform that monitors machines with plug-and-play sensors or custom integrations to any PLC, robot or sensor, and turns the data into utilization, downtime, OEE, production scheduling and maintenance workflows.
IoTFlows is a manufacturing intelligence platform that monitors machines with plug-and-play sensors or custom integrations to any PLC, robot or sensor, and turns the data into utilization, downtime, OEE, production scheduling and maintenance workflows.
Trusted by industry leaders
Customer Testimonials
50% less shift-changeover downtime
"Where was downtime actually coming from? We had no idea until we started using IoTFlows SenseAi. By tracking downtime categorization week to week and month to month, we could see exactly where our biggest problems were and track whether our fixes actually worked."
2x machine utilization
"SenseAi gave us eyes we never had before. Our team leaders can instantly see which machines are running, which are down, and identify issues immediately instead of discovering them hours later. That visibility transformed our ability to manage production."
< 1 week from the box to monitored machines
"The speed of implementation was remarkable. We went from limited visibility to complete operational transparency in less than a week. We're now identifying inefficiencies we didn't even know existed. IoTFlows has fundamentally changed how we approach manufacturing optimization."
Zero silent failures
"Continuous vibration monitoring gave us eyes we never had before. We can see tool crashes that would have been invisible, identify the exact moment and severity, and pull historical data to understand what went wrong."
One platform, eight modules. Every one runs on the same machine data.
Machine monitoring
Is it running, how much of the shift, and where did the stopped time go? Every machine, second by second.
Production tracking
Good and scrap parts against a shift goal, by machine, line and operator.
Maintain
Work orders opened from a downtime, an event rule, a meter or by hand.
Production Scheduler
Who runs what, on which machine, by when. Gantt, Kanban, an optimizer that proposes before it writes, and simulation.
Inventory
Parts and stock that move when a work order closes.
Alerts and integrations
Ten event types to email, push, SMS, Slack, Teams, Discord and webhooks.
Messaging and operator views
Chat, requests from the floor, Operator View and kiosk stations.
Apps and hardware
iOS, Android and Google TV wallboards. SenseAi, SenseAi Embedded, BeamTracker and the 4G/LTE router.
SenseAi
SenseAi Embedded
BeamTrackerCustom integrationsEnterprise
Any PLC, robot, sensor or ERP through the IoTFlows edge device and connectors built for your plant, as a scoped project.
Start with 10 machines for four weeks.
Put them on your bottleneck line and see where the time goes. SenseAi attaches magnetically in seconds and calibrates in under five minutes, with no PLC.
REAL-TIME PERFORMANCE & PRODUCTION TRACKING
See Every Second of Production. Hit Every Target.
Monitor OEE in real-time, spot bottlenecks the moment they occur, and track performance from individual machines to plant-wide operations.
- Live OEE monitoring and performance benchmarking across shifts
- Real-time production tracking
- Bottleneck identification and cycle time optimization
- Production variance alerts and target tracking
- Job progress visibility across all teams and production lines
DATA-DRIVEN DECISIONS
Reports That Actually Answer Your Questions
Stop digging through spreadsheets. Get reports customized to your shift schedules, operators, and departments. Track utilization, downtime patterns, and OEE metrics across all machines.
- Daily, weekly, monthly, quarterly, and yearly reporting
- Custom shift-based performance analysis
- Operator and machine benchmarking
- Exportable data for stakeholder presentations
- Historical trend analysis
DOWNTIME INTELLIGENCE
Turn Downtime Into Insights
Unplanned stops don't have to stay a mystery. Automatically record every downtime event, identify root-causes, and spot trends over time. Know exactly when, where, and why issues occur.
- Automated downtime event recording
- Detailed root-cause analysis and categorization
- Trend identification for recurring problems
- Customizable alerts based on your specific time thresholds
INTELLIGENT PRODUCTION PLANNING
Schedule Smarter. Execute Faster.
Scheduling that follows what is actually happening on the floor. Jobs are prioritized by due date and demand, every machine reports its progress live, and when priorities shift the optimizer proposes a new plan before anything changes.
- An optimizer that proposes the job order before it changes the schedule
- Demand-based production forecasting
- Live job status monitoring across all machines
- Dynamic schedule adaptation to changing priorities
- Drag-and-drop kanban interface for easy adjustments
MACHINE HEALTH ANALYTICS
7 Real-Time Health Scores
Monitor every aspect of machine health with AI-powered analytics that detect issues before they become failures
Stay Informed on Every Operation
Receive instant notifications for critical events, machine health changes, temperature anomalies, and vibration alerts. Your entire operation, monitored 24/7.
Health Monitoring
Track machine health scores and get alerted before failures occur
Temperature Alerts
Detect overheating and thermal anomalies in real-time
Vibration Detection
Monitor shock and vibration levels to prevent equipment damage
Downtime and Uptime Tracking
Get notified immediately when machines go offline or idle
Production Rate Monitoring
Get alerted when production throughput drops below targets
Part Inspection Alerts
Automatic reminders for quality checks based on parts count
Machine Health Critical
19%Overall health score has dropped below 45%
High Temperature Detected
78°CMotor temperature exceeding normal operating range
Production Rate Declining
68 parts/hrGradual decrease in production throughput detected
Excessive Vibration
8.2GShock levels indicate potential bearing failure
Machine Running
Machine is up and running
Extended Downtime
45minMachine has been idle for longer than scheduled
Health Score Declining
68%Gradual decrease in overall machine health detected
Temperature Rising
65°CBearing temperature trending upward
Vibration Spike
5.8GUnusual vibration pattern detected on X-axis
Inspection Overdue
1500 partsPart inspection threshold exceeded - immediate check required
Unplanned Downtime
120minMachine stopped unexpectedly during production
Health Score Declining
38%Gradual decrease in overall machine health detected
Machine Health Critical
19%Overall health score has dropped below 45%
High Temperature Detected
78°CMotor temperature exceeding normal operating range
Production Rate Declining
68 parts/hrGradual decrease in production throughput detected
Excessive Vibration
8.2GShock levels indicate potential bearing failure
Machine Running
Machine is up and running
Extended Downtime
45minMachine has been idle for longer than scheduled
Health Score Declining
68%Gradual decrease in overall machine health detected
Temperature Rising
65°CBearing temperature trending upward
Vibration Spike
5.8GUnusual vibration pattern detected on X-axis
Inspection Overdue
1500 partsPart inspection threshold exceeded - immediate check required
Unplanned Downtime
120minMachine stopped unexpectedly during production
Health Score Declining
38%Gradual decrease in overall machine health detected
Cooling System Inefficient
68°CCooling system not maintaining target temperature
Gearbox Temperature Rising
82°CGearbox operating above normal temperature range
Hydraulic Overheat
92°CHydraulic system temperature critically high
Seal Failure Imminent
22%Seal integrity degraded - replacement urgently needed
Air Pressure Fluctuating
65%Pneumatic system pressure showing instability
Lubrication Level Low
48%Automatic lubrication system level below threshold
Belt Tension Low
72%Drive belt tension below optimal operating range
Motor Health Critical
28%Multiple motor parameters outside acceptable range
Bearing Wear Detected
52%Bearing signature indicates accelerated wear patterns
Slow Production Detected
45 parts/hrProduction rate has dropped below expected threshold
Quality Check Required
500 partsQuality check needed after 1000 parts processed
Machine Running
Machine is up and running
Cooling System Inefficient
68°CCooling system not maintaining target temperature
Gearbox Temperature Rising
82°CGearbox operating above normal temperature range
Hydraulic Overheat
92°CHydraulic system temperature critically high
Seal Failure Imminent
22%Seal integrity degraded - replacement urgently needed
Air Pressure Fluctuating
65%Pneumatic system pressure showing instability
Lubrication Level Low
48%Automatic lubrication system level below threshold
Belt Tension Low
72%Drive belt tension below optimal operating range
Motor Health Critical
28%Multiple motor parameters outside acceptable range
Bearing Wear Detected
52%Bearing signature indicates accelerated wear patterns
Slow Production Detected
45 parts/hrProduction rate has dropped below expected threshold
Quality Check Required
500 partsQuality check needed after 1000 parts processed
Machine Running
Machine is up and running
Thermal Runaway Detected
95°CRapid temperature increase detected in control cabinet
Cold Chain Break
12°CRefrigeration unit temperature exceeded safe range
Pasteurization Temperature
68°CProcess temperature below pasteurization minimum
Fermentation Temp Drift
23°CFermentation tank temperature drifting from setpoint
Pump Cavitation Detected
6.4GUnusual vibration signature indicates pump cavitation
Shaft Misalignment
9.1GSevere vibration indicates potential shaft misalignment
Belt Slippage Detected
4.2GIntermittent vibration patterns suggest belt slippage
Rotor Imbalance
7.3GVibration analysis indicates rotor imbalance condition
Production Line Stalled
12 parts/hrProduction rate dropped to near zero - line may be stalled
Bottleneck Detected
58 parts/hrStation 3 causing downstream flow reduction
Cycle Time Increasing
73 parts/hrAverage cycle time trending upward over past hour
Shift Target Behind
340 unitsProduction 15% below target for current shift
Thermal Runaway Detected
95°CRapid temperature increase detected in control cabinet
Cold Chain Break
12°CRefrigeration unit temperature exceeded safe range
Pasteurization Temperature
68°CProcess temperature below pasteurization minimum
Fermentation Temp Drift
23°CFermentation tank temperature drifting from setpoint
Pump Cavitation Detected
6.4GUnusual vibration signature indicates pump cavitation
Shaft Misalignment
9.1GSevere vibration indicates potential shaft misalignment
Belt Slippage Detected
4.2GIntermittent vibration patterns suggest belt slippage
Rotor Imbalance
7.3GVibration analysis indicates rotor imbalance condition
Production Line Stalled
12 parts/hrProduction rate dropped to near zero - line may be stalled
Bottleneck Detected
58 parts/hrStation 3 causing downstream flow reduction
Cycle Time Increasing
73 parts/hrAverage cycle time trending upward over past hour
Shift Target Behind
340 unitsProduction 15% below target for current shift
Material Shortage
18minProduction paused due to raw material depletion
Emergency Stop Triggered
0Safety system activated - machine stopped immediately
Scheduled Downtime
45minPlanned maintenance window in progress
System Recovery
Equipment successfully recovered from fault condition
Maintenance Complete
Scheduled maintenance completed, equipment operational
Line Startup Complete
Production line successfully started and running
Calibration Check Needed
950 partsSensor calibration verification due after production run
Tool Wear Check
850 partsCutting tool inspection recommended based on part count
Scheduled Inspection Due
1200 partsRegular maintenance inspection window approaching
Critical Inspection Required
2500 partsImmediate quality inspection needed - defect rate increasing
Reject Rate Increasing
18 defects/hrQuality rejects up 12% from previous hour
Efficiency Declining
76%Overall equipment effectiveness trending downward
Material Shortage
18minProduction paused due to raw material depletion
Emergency Stop Triggered
0Safety system activated - machine stopped immediately
Scheduled Downtime
45minPlanned maintenance window in progress
System Recovery
Equipment successfully recovered from fault condition
Maintenance Complete
Scheduled maintenance completed, equipment operational
Line Startup Complete
Production line successfully started and running
Calibration Check Needed
950 partsSensor calibration verification due after production run
Tool Wear Check
850 partsCutting tool inspection recommended based on part count
Scheduled Inspection Due
1200 partsRegular maintenance inspection window approaching
Critical Inspection Required
2500 partsImmediate quality inspection needed - defect rate increasing
Reject Rate Increasing
18 defects/hrQuality rejects up 12% from previous hour
Efficiency Declining
76%Overall equipment effectiveness trending downward
SHOP FLOOR EMPOWERMENT
Tools Built For The People Who Build Your Products
Equip your operators with intuitive tools that make hitting production goals effortless. Real-time machine status, simplified downtime tracking, and instant collaboration and file sharing - all accessible from tablets, phones, or shop floor displays.
- Intuitive iPad and mobile interface for shop floor
- One-tap downtime classification and work order creation
- Real-time machine status visibility
- Instant alerts and notifications
- Seamless collaboration between operators and management
TEAM COLLABORATION & CONNECTED OPERATIONS
Align Teams. Respond Faster. Run Smarter.
Streamline communication and collaboration across your entire operation. IoTFlows empowers teams to submit maintenance requests, file issues, manage work orders, and share critical files - all from one unified platform. Track jobs in real-time, coordinate team assignments, and ensure everyone from operators to managers stays informed and aligned.
- Real-time mobile alerts and instant notifications
- Collaborative downtime classification and root-cause tracking
- Unified job progress visibility across all teams and shifts
- Work order integration and maintenance workflow automation
- Cross-functional communication from floor to executive level
ENTERPRISE INTEGRATION & DATA UNIFICATION
Break Down Data Silos. Automate Across Systems.
Stop manually bridging the gap between shop floor and top floor. IoTFlows unifies production data from across your facility and connects it to your ERP and other business systems. Enable real-time visibility across departments, trigger automated workflows based on production events, and eliminate manual data entry. Your operations data becomes the single source of truth that drives smarter decisions and faster response times.
- Bi-directional ERP integration: SAP, Oracle, Epicor, and many more
- Seamless data sync capabilities eliminate manual entry and reduce errors
- Real-time production visibility for finance, operations, and management
- Event-driven automation: trigger workflows, notifications, and actions
- API-first architecture for custom integrations and advanced automation
Questions people ask
Yes. SenseAi and SenseAi Embedded read vibration from the outside of the machine and BeamTracker counts parts crossing a laser beam, so nothing connects to the controls. For Enterprise customers, IoTFlows also reads PLC, robot and sensor data through the IoTFlows edge device.
SenseAi and SenseAi Embedded attach magnetically in seconds and calibrate in under five minutes; BeamTracker bolts on with the supplied mount in 10 to 20 minutes. A machine shows its status on the Assets page within a minute of coming online.
Yes. The Production Scheduler plans jobs on the same machines the sensors monitor: list, table, Gantt, Kanban and calendar views, drag-and-drop, an optimizer that proposes before it writes, a simulation sandbox, an ERP import, and a work queue for operators.
Yes. Maintain is the IoTFlows CMMS: work orders from the board, a classified downtime, a machine event, a meter or an operator's request, with preventive recurrence, checklists, parts from Inventory and native iOS and Android apps.
On every plan: Slack, Microsoft Teams and Discord, email, SMS and push, signed webhooks, a schedule import from any ERP export, and a REST API with an IoTFlows-issued key. For Enterprise customers: two-way ERP connectors and PLC, robot and sensor data through the edge device.
Per monitored machine. The Pro plan is $119 per device per month billed monthly and $99 on an annual plan paid upfront, with volume discounts from 10 devices. Hardware is a one-time purchase: SenseAi $149, SenseAi Embedded $199, BeamTracker $299. Enterprise is $249 per device per month billed monthly, with the same discounts.
Yes. Data is encrypted at every step: from the device at the edge, in transit over TLS with SHA-256 certificates, and at rest in the IoTFlows cloud. The 4G/LTE router can keep devices off the plant network entirely. Access is by organization, role and machine list, with two-step authentication on every account and an audit log of every change.
Two things, in one product. The sensors need no PLC, so any machine with a motor or a part path reports in minutes, and for Enterprise customers IoTFlows integrates with any PLC, robot or ERP as a project. And the Production Scheduler and Maintain run on the same machine data, so a downtime becomes a work order and a schedule uses the real part count.
Start Monitoring Your Machines Today
Join the 100+ manufacturers that run IoTFlows.