four zones · continuous monitoring.
Each zone of your autoparts plant has different risks: CNC and machining, ESD-controlled clean rooms, CFE GDMTO energy, operational continuity. One platform covers all four.
CNC, lathes, presses
Each machine with current-signature analysis · detects bearings, servos, spindle degrading. Predictive maintenance with real operating hours (not fixed calendar) · data-driven maintenance scheduling.
ESD clean rooms
Temperature + humidity + differential pressure sensor in ISO 7 / 8 clean rooms. Continuous PM2.5 / PM10 / VOC sensor · fine-assembly compliance · documented ESD-controlled.
CFE GDMTO energy
Three-phase meter on main panel + per-line or per-machine sub-metering · power-factor analysis · contracted-demand management. kWh-per-part efficiency visible for OEM ESG audit.
operational continuity
Backup generator with current meter + diesel level sensor + generator-room temperature sensor. Critical UPS. Generator always ready · OEM client always covered.
Out of scope: machine process control · MES · ERP · PLM. AstreaIoT does not replace them; if your MES or ERP needs operating-hours or per-part energy data, we integrate via Custom Integration.
what we protect · what we prevent.
- +CNC, lathe or press degradation detection 2-4 weeks ahead · scheduled change
- +Clean room in spec (humidity + PM2.5 + differential pressure) · uncontaminated fine assembly
- +kWh-per-part efficiency per line and shift · ESG-ready for OEM audit
- +Capacitor bank justified with real data · approximate payback in 3-6 months
- +Generator always ready · Tier 0 OEM client always covered in blackout
- ✕JIT downtime >2 hr that moves OEM line downstream · significant contractual penalty
- ✕Whole lot rejected by OEM from clean-room contamination
- ✕Permanent CFE GDMTO surcharge from low power factor
- ✕Emergency CNC repair vs scheduled maintenance · several times the cost
- ✕OEM ESG audit without data · client puts supplier on "watchlist" or cancels contract
ten use cases · four critical areas.
for the operations director.
Operations Director + Maintenance Lead. Three cases · CNC bearing degrading, press with deviating servo, predictive maintenance scheduling with real hours. Each machine with current-signature analysis.
for the OEM quality director.
OEM Quality Director (auditor) + internal Quality Director. Three cases · clean room with out-of-range humidity, lost differential pressure, elevated PM2.5 contaminates fine assembly. Documented ESD-controlled for OEM audit.
for the CFO and OEM ESG auditor.
CFO + OEM ESG auditor (Toyota Production System, GM Sustainability, etc.). Two cases · low power factor, ESG kWh-per-part report for OEM audit. CFE GDMTO with continuous sub-metering.
for the plant director and JIT lead.
Plant Director + JIT Lead. Two cases · generator does not start on blackout (plant down for OEM client), STPS audit with log full of gaps. Documented operational continuity for OEM client.
three compliances + OEM audit · one platform covers all.
For Tier 1 multi-plant operators, national dashboard with comparable per-plant metrics — exactly what the OEM ESG auditor wants to see.
from sensor to report · every five minutes · without human intervention
Five steps. They run in parallel across all your sites, all the time. When something crosses a threshold, the flow completes in under five minutes — alert delivered, response logged, inspector-ready evidence captured.
measure
Sensors measure temperature, humidity, current, door-open, leak and other magnitudes every five minutes — no operator required.
detect
The system compares each reading against the threshold configured per recipe · per site · per equipment. Threshold crossing triggers the flow.
alert
The alert routes to the right person via WhatsApp, email or push · per role and schedule configured.
respond
The operator acts from the dashboard or mobile app. The corrective action goes into an immutable log with timestamp + signature.
audit
Everything becomes part of the audit package · time series, critical events, corrective actions, NOM report ready in two clicks.
Five steps · no manual operators · no paperwork · no gaps.
five phases · per plant.
site survey per plant
1-2 daysTechnical visit + inventory of CNC, lathes, presses, clean rooms, CFE panel · STPS checklist · Tier 0 OEM SLA identification.
physical installation
4-5 dayscurrent meter per critical machine + differential-pressure sensor + temp/humidity/PM in clean rooms + panel three-phase meter · no operational shutdown.
configuration + calibration
2 daysPer-machine thresholds · baseline learned in 5-7 days · per-OEM client report templates (TPS, GM, etc.) · WhatsApp alerts per role.
team training
1 dayPlant Director + Maintenance Lead + Quality Director + JIT Lead · each role trains on their flow.
30 days of support + first OEM audit
30 daysAstreaIoT specialist available · first monthly report delivered · first OEM (ESG/TPS) audit backed by continuous data.
For Tier 1 multi-plant operators: after the first pilot plant, phases compact to 10-14 days per plant.
common questions · before the quote.
does it work with CNC, lathes and presses from any vendor?
Yes. Current-signature analysis is done on external current meter on the motor · without touching machine control · without operational shutdown. Compatible with Fanuc, Siemens, Mazak, Okuma, DMG Mori and others.
how are clean-room sensors calibrated?
Temperature, humidity, differential-pressure and PM sensors calibrated in an accredited laboratory before deployment. Validity tracked per equipment. Recalibration every 12 months · we keep the calendar.
does it integrate with the plant MES or ERP?
Yes · via Custom Integration. We connect you to SAP, Oracle, Microsip, proprietary MES (Fanuc, Siemens) or a custom system. Data arrives directly in your central system.
does the OEM ESG report cover TPS or GM Sustainability templates?
Yes · pre-configured templates for Toyota Production System, GM Sustainability, Nissan PPAP, BMW Lieferantenmanagement. PDF downloadable in three clicks with your logo and signatures. Custom template via Custom Integration if your OEM has a specific one.
what happens if the plant internet goes out?
The gateway has 32-hour backup and local buffer. Sensors keep recording · everything syncs on reconnect. Included cellular backup takes over if the outage prolongs.
does current-signature analysis work on spindle and servo?
Yes · any rotating equipment. The algorithm learns the normal signature in 5-7 days and alerts when it detects degradation 2-4 weeks before failure. Spindle, servo, main motor, ballscrew, hydraulic pump.
what happens if a machine goes to major maintenance?
Sensors are portable · removed and mounted on the backup machine in 15 minutes. The system automatically maps the new assignment. No penalty or fee.