INDUSTRIAL IOT CASE STUDY

IIOT Gas Anomaly Detection System for Daikin

Real-time monitoring solution using nRF52, MQTT, Power BI, and AWS for predictive maintenance

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PROJECT OVERVIEW

Industrial IoT Gas Monitoring Platform

Real-time monitoring solution using nRF52, MQTT, Power BI, and AWS for predictive maintenance

Pyzen Technologies developed a comprehensive IIOT solution for Daikin to monitor gas anomalies in their manufacturing facilities. This system leverages nRF52 microcontrollers for sensor data collection, MQTT for real-time communication, AWS for cloud processing, and Power BI for advanced visualization and reporting. The solution enables Daikin to detect gas leaks and anomalies in real-time, preventing potential hazards, reducing downtime, and optimizing maintenance schedules. By implementing predictive maintenance capabilities, Daikin has significantly improved operational safety while reducing costs associated with unplanned equipment failures. Our system processes thousands of data points per second from sensors deployed across Daikin’s manufacturing facilities, providing actionable insights through an intuitive dashboard that can be accessed from any device.

Strategy-led delivery
AI, cloud, web, and automation expertise
Secure engineering practices

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THE CHALLENGE

The Industrial Safety Challenge

Daikin, a global leader in air conditioning solutions, faced significant challenges in their manufacturing facilities: • Gas Leak Detection: Traditional systems had slow response times and high false positive rates • Predictive Maintenance: Lack of real-time data made it difficult to predict equipment failures • Multi-location Monitoring: Needed a centralized system for multiple manufacturing facilities • Regulatory Compliance: Strict safety regulations required comprehensive monitoring and reporting • Cost Efficiency: Manual monitoring processes were labor-intensive and expensive The company needed a scalable, reliable solution that could provide real-time insights while integrating with their existing infrastructure.

Strategy-led delivery
AI, cloud, web, and automation expertise
Secure engineering practices

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AICloudWebAutomation

THE SOLUTION

Our IIOT Technical Solution

We designed and implemented a comprehensive IIOT ecosystem tailored to Daikin’s specific requirements: nRF52 Microcontrollers: Low-power wireless sensors deployed throughout facilities to monitor gas levels, temperature, and pressure. MQTT Protocol: Lightweight messaging protocol for efficient real-time data transmission from edge devices to the cloud. AWS IoT Core: Secure cloud platform for device management, data processing, and storage. AWS Lambda & Kinesis: Serverless computing and data streaming for real-time anomaly detection. Power BI Dashboards: Comprehensive visualization tools for operational insights and regulatory reporting. Mobile Alerts: Instant notifications to facility managers when anomalies are detected.

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Real-time Monitoring: Continuous tracking of gas levels across all facilities
Predictive Analytics: AI-powered algorithms to predict potential failures
Instant Alerts: Immediate notifications for critical anomalies
Cloud Integration: Seamless AWS cloud connectivity for data processing
Mobile Access: Remote monitoring capabilities from any device
Historical Analysis: Comprehensive reporting for trend analysis

01Smart Data Ingestion

02AI Transformation

03Dynamic Routing

04Live Monitoring

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DELIVERY PROCESS

Implementation Process

A structured delivery model ensuring reliability, visibility, and controlled rollouts.

Requirement Analysis

Comprehensive assessment of Daikin's facilities and safety requirements

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Sensor Deployment

Strategic placement of nRF52 sensors throughout manufacturing facilities

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Cloud Architecture

Design and implementation of AWS IoT infrastructure

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Dashboard Development

Creation of Power BI dashboards for visualization and reporting

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MEASURABLE IMPACT

Measurable Business Impact

The implementation delivered significant operational and safety improvements for Daikin:

99.9%

Detection Accuracy

Highly accurate anomaly detection with minimal false positives

200ms

Response Time

Near real-time alerting for critical conditions

45%

Maintenance Cost Reduction

Predictive maintenance reduced unexpected downtime

100%

Regulatory Compliance

Comprehensive reporting for safety regulations

“Pyzen's IIOT solution has transformed our safety monitoring capabilities. The real-time alerts have prevented potential incidents, and the predictive maintenance features have significantly reduced our downtime.”
James Watanabe — Operations Director, Daikin

VERIFIED REVIEWS

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CASE STUDY FAQ

Frequently Asked Questions

Direct answers about this case study and implementation.

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01 How does the nRF52 microcontroller benefit this solution?

The nRF52 provides low-power wireless connectivity, enabling years of battery life for sensors while maintaining reliable communication with the cloud gateway, making it ideal for industrial IoT applications.

02 Why was MQTT chosen as the communication protocol?

MQTT is a lightweight publish-subscribe network protocol that transports messages between devices. It's designed for constrained devices and low-bandwidth, high-latency networks, making it perfect for IIOT applications.

03 How does the system ensure data security?

We implemented multiple security layers including TLS encryption for data in transit, AWS IoT device authentication, fine-grained access control policies, and regular security audits to protect sensitive operational data.

04 Can the system integrate with existing industrial equipment?

Yes, the solution is designed with flexibility in mind. We can interface with existing PLCs, SCADA systems, and industrial equipment through various protocols including Modbus, OPC UA, and others.

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