IoT solutions for manufacturing (IIoT)
SumatoSoft builds end-to-end IIoT solutions that span edge data collection through applications, analytics, and integrations. We integrate industrial IoT systems to give production teams a full overview of equipment data and enable them to act on it.
- ISO 9001:2015 & ISO/IEC 27001:2022 certified
- Security approach aligned with IEC 62443
What we deliver
We add AI on top of your existing IoT system without touching production-critical components. Your devices, gateways, data pipelines, and dashboards remain intact. The AI layer operates independently, consuming data through secure connectors and APIs. In practice, this means:
Discovery and business analysis
We help you define goals, KPIs, user roles, workflows, and what “done” means, then we produce a pilot scope, success criteria, and a prioritized backlog.
Architecture
We help you choose the right pattern with edge, cloud, or hybrid calculation based on latency, reliability, security, and data ownership. We also document your data flows and interfaces.
Data pipeline
We help you collect, normalize, store, and serve industrial data with monitoring and data quality checks. This facilitates offline development and safe recovery.
Applications
We develop dashboards and operator tools that match your workflows: alerts, shift views, asset history, and actionable states.
Integrations
We connect to SCADA, MES, ERP, CMMS, QMS, and data platforms via APIs, connectors, and event pipelines without disrupting what already runs in production.
Analytics
We use rules, statistics, or ML when the data supports it: anomaly detection, condition monitoring, forecasting, and root-cause assistance.
Support and rollout
We move from pilot to production with observability, documentation, training, and a rollout plan across assets, lines, and sites.
We build for both SMB manufacturers and enterprise rollouts
SMB manufacturers
You need a fast, low-risk start that proves value before scaling. We offer:
- Pilot-first approach. A focused scope tied to one asset group, one line, or one pain point.
- Minimal infrastructure. Edge collection and a lightweight architecture that fits your current setup.
Start with existing data. PLC/SCADA tags, historical data, alarms, and maintenance logs.
Enterprises
You need governance, security, and a rollout path that works across plants and teams.
- Scale by design. Reference architecture and reusable components for multi-site deployment.
- Governance and access control. Roles, permissions, audit trails, and change management built into the system.
- Security that fits OT realities. Segmentation-aware designs, controlled data flows, and monitored integrations.
- MES/ERP integration-ready. Data models and interfaces that connect IIoT signals to enterprise workflows.
Rollout across lines and plants. Standardize where it helps, localize where it’s required.
Manufacturing benefits of integrating IIoT
Book your free IoT strategy call
Not sure where to start? Chat with our lead architects to find the high-impact IoT wins for your manufacturing.
Our recent AI cases
The system has produced a significant competitive advantage in the industry thanks to SumatoSoft’s well-thought opinions.
They shouldered the burden of constantly updating a project management tool with a high level of detail and were committed to producing the best possible solution.
I was impressed by SumatoSoft’s prices, especially for the project I wanted to do and in comparison to the quotes I received from a lot of other companies.
Also, their communication skills were great; it never felt like a long-distance project. It felt like SumatoSoft was working next door because their project manager was always keeping me updated. Initially.
We tried another company that one of our partners had used but they didn’t work out. I feel that SumatoSoft does a better investigation of what we’re asking for. They tell us how they plan to do a task and ask if that works for us. We chose them because their method worked with us.
SumatoSoft is great in every regard including costs, professionalism, transparency, and willingness to guide. I think they were great advisors early on when we weren’t ready with a fully fleshed idea that could go to market.
They know the business and startup scene as well globally.
SumatoSoft is the firm to work with if you want to keep up to high standards. The professional workflows they stick to result in exceptional quality.
Important, they help you think with the business logic of your application and they don’t blindly follow what you are saying. Which is super important. Overall, great skills, good communication, and happy with the results so far.
They are very sharp and have a high-quality team. I expect quality from people, and they have the kind of team I can work with. They were upfront about everything that needed to be done.
I appreciated that the cost of the project turned out to be smaller than what we expected because they made some very good suggestions. They are very pleasant to work with.
The Rivalfox had the pleasure to work with SumatoSoft in building out core portions of our product, and the results really couldn’t have been better.
SumatoSoft provided us with engineering expertise, enthusiasm and great people that were focused on creating quality features quickly.
SumatoSoft succeeded in building a more manageable solution that is much easier to maintain.
When looking for a strategic IT-partner for the development of a corporate ERP solution, we chose SumatoSoft. The company proved itself a reliable provider of IT services.
Thanks to SumatoSoft can-do attitude, amazing work ethic and willingness to tackle client’s problems as their own, they’ve become an integral part of our team. We’ve been truly impressed with their professionalism and performance and continue to work with a team on developing new applications.
We are completely satisfied with the results of our cooperation and will be happy to recommend SumatoSoft as a reliable and competent partner for development of web-based solutions
Together with the team, we have turned the MVP version of the service into a modern full-featured platform for online marketers. We are very satisfied with the work the SumatoSoft team has performed, and we would like to highlight the high level of technical expertise, coherence and efficiency of communication and flexibility in work.
We can say with confidence that SumatoSoft has realized all our ideas into practice.
Three ways to start: greenfield, legacy-first, or scaling
Most manufacturing environments are mixed. You might have a modern line next to equipment that’s been running for 15 years, plus a historian that only a few people fully trust. Our job is to build an IIoT layer that fits what you have today and improves visibility quickly.
Greenfield (from scratch)
Scaling
Brownfield (legacy-first)
Greenfield (from scratch)
You’re launching a new line, plant, or digital program and want a clean architecture from day one. We’ll help you:
- Define the sensor and signal model for the use case
- Select gateways and edge approach (buffering, local logic, offline handling)
- Build the data platform (cloud, on-prem, or hybrid)
- Deliver dashboards and operator/maintenance tools
- Integrate with enterprise systems when you’re ready (MES/ERP/CMMS)
Scaling
You already have some digital systems in place. We extend them into an IIoT layer that delivers better operational outcomes. We’ll help you:
- Connect to your existing SCADA/MES/historians and standardize the data model
- Add edge buffering and monitoring
- Build role-based dashboards and workflows (operations, maintenance, engineering)
- Close the gaps: data quality, alerts with context, integrations with CMMS/ERP
- Prepare the solution for rollout across lines, sites, and plants
Brownfield (legacy-first)
You already have production systems and data, but it’s fragmented or hard to use. The fastest path is to start with what exists. We’ll help you:
- Use PLC/SCADA tags, historians, alarms, and maintenance logs as the first data sources
- Add sensors only when the failure mode requires a new signal (not by default)
- Integrate without disrupting operations
- Prioritize minimal intervention and safe deployment, with downtime avoided where possible
How we apply IoT to tackle issues specific to manufacturing
Unplanned downtime on critical equipment
- Problem: stops happen without early signals; maintenance was reactive
- Solution: condition monitoring + event context + CMMS-linked alerts
- Outcome: earlier intervention, fewer surprise failures, faster response on shift
No single view of line performance
- Problem: stop reasons and micro-stops were not classified consistently
- Solution: machine-state collection + stop taxonomy + shift dashboards
- Outcome: visible structure of loss, faster root-cause cycles, fewer “unknown” stops
Quality issues with slow root-cause analysis
- Problem: batch data existed, but process parameters were not linked to outcomes
- Solution: traceability links + parameter capture + quality event timeline
- Outcome: quicker containment and audit-ready traceability
Energy cost rise without an obvious breakdown
- Problem: bills were visible, but consumption drivers were not
- Solution: metering + production context + energy-per-unit dashboards
- Outcome: reduced waste and clearer levers for cost control
IIoT use cases we work with
- Operations visibility (OEE, downtime)
- Maintenance (condition monitoring, PdM)
- Quality and traceability
- Energy monitoring
- Asset tracking and remote monitoring
Integrations that connect signals to business workflows
IIoT is valuable when production signals flow into the systems that teams use to run the plant. We design integrations so data stays consistent across OT and IT, and so actions are visible across systems.
Where we integrate
- MES (production execution, performance, downtime reasons)
- ERP (orders, materials, costing context)
- CMMS/EAM (work orders, asset history, planned vs reactive maintenance)
- QMS (quality events, inspections, nonconformities, CAPA)
- WMS (inventory, movement events, traceability links)
How we integrate
- APIs for stable, documented interfaces
- Event-driven pipelines (message bus/streaming) for real-time propagation
- ETL/ELT when you’re consolidating historical data or feeding analytics platforms
Security and reliability built in
Industrial IoT lives at the intersection of production and IT. That means that access must be controlled, and data must keep flowing even when networks and environments are imperfect. We treat security and reliability as design constraints from day one.
Access and segmentation
Data protection
Edge and device hardening
Observability and incident readiness
Access and segmentation
Data protection
Edge and device hardening
Observability and incident readiness
A delivery path that reduces risk and supports scale
IIoT succeeds when it moves from “we connected data” to “teams rely on it every day.”
We define one problem, one asset group (or line), and a target for measurement. The output is a pilot plan with KPIs, data sources, user roles, and a “done” definition.
We connect to available signals, implement the pipeline, and deliver the first workflows. If data gaps block the use case, we address them explicitly (including when sensors are actually needed).
Before scaling, we make the system dependable by implementing monitoring, access controls, auditability, failure handling, and operational documentation.
We create a rollout plan that defines what is standardized, what is configurable per site, how integrations are managed, and how changes are governed. Then we expand across assets and production lines with predictable effort and consistent outcomes.
| What you get at each stage | Description |
|---|---|
Architecture and data model |
Reference architecture, data flows, asset model, and the logic behind edge/cloud/hybrid choices. |
Integration specifications |
Interfaces, data contracts, mapping rules, and responsibilities across systems (MES/ERP/CMMS/QMS/WMS). |
Backlog + scope boundary |
A prioritized backlog plus a scope boundary. |
UX prototypes and dashboards |
Role-based screens for operations, maintenance, and engineering customized to your workflows. |
Pilot plan + success criteria |
KPIs, data sources, acceptance criteria, and an agreed definition of “pilot success.” |
Support materials (when included) |
Runbooks, monitoring setup, escalation paths, and operational documentation for day-to-day use. |
How we work
The hard part in IIoT is ensuring integrations are safe and rollouts are controlled. We run delivery with an AI-driven software development lifecycle: start with hypotheses and a tight scope, define human/agent responsibilities, validate early with evaluations, deploy with monitoring, and keep a feedback loop after go-live.
How AI shows up in our delivery
- Discovery: we turn plant docs and logs into testable hypotheses, KPIs, and failure signals, and validate them with stakeholders.
- Build + QA: we use AI to speed up scaffolding, test coverage, and documentation, while humans own design decisions, reviews, and sign-offs.
- Deploy + operate: we treat deployment as controlled activation with monitoring, rollback/containment, and a structured feedback loop for improvements.
Who’s on our team
- Business Analyst (requirements, workflows, KPIs)
- Solution Architect (OT/IT architecture, security, rollout design)
- Data Engineer (pipelines, quality, observability)
- Embedded/Edge Engineer (gateways, buffering, device integration)
- QA Engineer (test strategy across data, integrations, and UI)
- Frontend/Backend Engineers (apps, APIs, integrations)
Frequently asked questions
Do we need to buy sensors first?
Not always. Many pilots start with what you already have: PLC/SCADA tags, historians, alarms, and maintenance logs. We add sensors when the use case requires a signal you can’t get otherwise.
Can you deploy on-prem, or does it have to be cloud?
Both are possible. We design for cloud, on-prem, or hybrid, depending on latency, reliability, security, and data ownership requirements.
Who owns the data?
You do. We build the system around your data governance: access control, retention rules, and auditability.
How do you reduce the risk of production disruption?
We start with a narrow scope, connect read-first where possible, use edge buffering and offline-aware pipelines, and validate with operations and maintenance before expanding.
Let’s start
If you have any questions, email us [email protected]
