Are you trying to reduce unplanned downtime, improve efficiency, and create a safer, smarter factory? You’ve probably come across the term Industrial Internet of Things (IIoT) and wondered: How do I actually implement it in my plant without disrupting daily operations?
That’s exactly what we’ll cover in this guide. At Rejig Digital, we don’t just talk about IIoT — we implement it every day through our proprietary Arete IIoT platform. From connecting machines to tracking workforce productivity with our Connected Workmen solution, we’ve helped manufacturing leaders like you modernize operations and achieve measurable ROI.
Why IIoT Implementation Matters Today
The manufacturing industry is under constant pressure:
• Unplanned equipment failures leading to production losses.
• Rising operational costs due to inefficient processes.
• Quality challenges without real-time visibility.
• Workplace safety issues in high-risk environments.
IIoT is not just about connecting machines. With platforms like Arete, it helps you:
• Predict and prevent machine failures.
• Optimize energy consumption.
• Gain real-time visibility of workers and assets.
• Improve compliance and safety standards.
How We Implemented Arete for a Leading Manufacturer
Recently, we deployed Arete IIoT for a large pharmaceutical manufacturer facing equipment downtime and workforce safety challenges.
Here’s how we solved it:
• Installed vibration and temperature sensors on critical machinery.
• Deployed Arete Connected Workmen solution with smart wearables to monitor worker safety and location in real time.
• Integrated the platform with their ERP and MES systems for seamless data flow.
• Set up predictive maintenance alerts and digital dashboards accessible to plant managers.
The results?
• 30% reduction in unplanned downtime.
• Real-time workforce visibility, ensuring worker safety and compliance.
• Significant energy savings through optimized operations.
👉 This isn’t theory — it’s a live example of how Arete makes manufacturing smarter, safer, and more efficient.
Step-by-Step Guide to Implementing IIoT in Your Plant
1. Assess Your Current Plant Readiness
Ask yourself:
• Are my machines IoT-ready, or do they need retrofitting?
• Do I have network infrastructure capable of real-time data transfer?
• Am I already capturing data, and if yes, am I using it effectively?
2. Define Your Business Goals
IIoT should drive measurable value. Consider:
• Do you want to reduce downtime?
• Improve worker safety and compliance?
• Enhance quality control?
• Drive sustainability by lowering energy use?
3. Choose the Right IIoT Platform (Arete Advantage)
This is where Rejig Digital’s Arete IIoT platform comes in. Unlike generic platforms, Arete is purpose-built for industrial manufacturing plants.
With Arete, you get:
• Machine Connectivity: Real-time monitoring of equipment performance.
• Connected Workmen: Worker tracking and safety management via smart wearables.
• Integration-Ready: Seamless integration with ERP, MES, and SCADA systems.
• Secure & Scalable: Enterprise-grade security and future-ready scalability.
4. Start Small with a Pilot Project
Rather than a plant-wide rollout, begin with a specific use case:
• Predictive maintenance on one production line.
• Worker safety monitoring in a high-risk area.
• Energy tracking for a single department.
👉 Prove value, then scale.
5. Deploy Sensors, Gateways & Connected Devices
• Smart Sensors: Capture vibration, temperature, energy consumption.
• Connected Workmen Devices: Smart helmets, wristbands, or wearables for real-time worker tracking.
• Edge Gateways: Ensure reliable data transfer to the Arete platform.
6. Build Real-Time Dashboards & Analytics
With Arete dashboards, your teams can:
• Monitor machine health in real time.
• Receive alerts before breakdowns happen.
• Track worker movements and ensure compliance with safety standards.
7. Secure Your IIoT Deployment
Cybersecurity is non-negotiable. With Arete, you benefit from:
• End-to-end data encryption.
• Role-based access controls.
• Compliance with ISO and industry safety standards.
8. Train and Empower Your Workforce
IIoT is successful only when your people embrace it.
• Train plant managers and operators on dashboards.
• Educate workers on wearable devices and safety features.
• Build a data-driven culture.
9. Scale & Optimize
Once your pilot delivers ROI, extend IIoT across the plant:
• Add more machines.
• Expand to multiple sites.
• Introduce advanced use cases like digital twins and supply chain visibility.
Quick Checklist for Manufacturers
- Assess plant readiness (machines + network)
- Define business goals (downtime, quality, safety, energy)
- Choose the right platform (Arete for Manufacturing)
- Pilot with one use case
- Deploy sensors, gateways & Connected Workmen devices
- Build dashboards & set predictive alerts
- Secure your IIoT environment
- Train and empower employees
- Scale across operations
Final Thoughts
So, let me ask you:
• Do you know which machines in your plant are costing you the most downtime?
• Can you track worker safety in real time right now?
• Are you ready to move from reactive firefighting to proactive decision-making?
At Rejig Digital, we’ve already helped leading manufacturers implement IIoT with Arete, our purpose-built platform for smart, connected factories. From machine monitoring to Connected Workmen safety tracking, we ensure you see measurable business impact.
👉 Ready to explore how Arete can transform your plant? Request a Free IIoT Readiness Assessment and let’s chart the roadmap together.
Frequently Asked Questions (FAQ)
1. How do I start implementing IIoT in my plant?
Begin with a readiness assessment of your machines and network. Define your business goals (downtime reduction, quality control, safety, energy savings), then choose a trusted IIoT platform like Arete by Rejig Digital. Start with a pilot project before scaling plant-wide.
2. What are the main benefits of IIoT for manufacturers?
- Predictive maintenance to avoid costly breakdowns
- Real-time visibility into machines and workers
- Higher productivity and efficiency
- Improved safety with solutions like Connected Workmen
- Lower energy costs through optimized usage
3. What is the Connected Workmen solution?
Connected Workmen is a workforce tracking and safety management system within Arete IIoT platform. Workers use smart wearables (helmets, wristbands, badges) to track their location, ensure safety compliance, and alert supervisors in case of accidents or emergencies.
4. How long does it take to implement IIoT in a manufacturing plant?
A pilot project can usually be implemented in 8–12 weeks, depending on complexity. A full plant-wide rollout may take several months but is done in phases to minimize disruption. With Arete, we ensure a faster time-to-value.
5. Is IIoT secure for sensitive manufacturing data?
Yes, but cybersecurity must be a priority. Arete ensures data is encrypted end-to-end, uses role-based access control, and complies with industry standards like ISO 27001 and NIST to protect sensitive manufacturing data.
6. What industries benefit the most from IIoT?
IIoT benefits automotive, aerospace, pharmaceuticals, chemicals, heavy industries, and FMCG manufacturing. Any industry where machine uptime, worker safety, and efficiency are critical can see immediate results.
