ACME’s Journey to Scalable Condition Monitoring
- Chakravarthi Gera
- Sep 21
- 2 min read
Client Overview
ACME, a leading industrial service provider specializing in condition monitoring, faced a growing challenge: managing and analyzing data from thousands of machines across multiple factories in Asia. Their existing infrastructure was fragmented, relying on disparate tools and siloed databases, which hindered operational efficiency and timely fault detection.
Business Challenge
ACME’s operations were burdened by:
Multiple SQL databases with incompatible versions
Siloed data that obstructed comparative analysis
A mix of third-party monitoring tools and sensors
Limited analytics capabilities across platforms
High dependency on manual data handling and reporting
The company needed a centralized, scalable platform that could:
Ingest data from any sensor or handheld device
Normalize and store massive volumes of data efficiently
Provide real-time visibility into asset health
Eliminate vendor lock-in and support offline deployments
Solution Delivered By Hopnet
We partnered with partnered with ACME to build a custom condition monitoring platform that could unify data ingestion, analysis, and reporting across all client sites.
Key Features of the Solution
Universal Data Ingestion: Custom connectors were developed to ingest data from virtually any vibration sensor, handheld device, or third-party system, ensuring full compatibility and eliminating the need for proprietary tools.
Scalable Architecture: The platform currently handles data from over 10,000 measuring points, demonstrating its ability to scale across large industrial environments.
ClickHouse Integration: Leveraging ClickHouse, a high-performance OLAP database, the system processes over 20 million records per day, with query speeds reduced from 4 seconds to just 10 milliseconds for 43,000 data points.
Offline Capability: The platform supports offline data staging, meeting the needs of factories with limited connectivity or strict data governance requirements.
One-Touch Deployment: Designed for ease of use, the system can be deployed without specialized software expertise, enabling rapid rollout across diverse client environments.
Key Outcomes
1. Centralized Monitoring Across Asia
ACME now has a single pane of glass view of all client sites
Real-time dashboards provide instant insights into machine health
2. Operational Efficiency
Analysts no longer rely on multiple tools or manual data reconciliation
Reporting time reduced from hours to minutes
3. Improved Data Reliability
Normalized data ingestion ensures consistency across sources
Eliminated compatibility issues between different SQL versions
4. Enhanced Customer Experience
Faster fault detection and reporting
Reduced machine downtime across client factories
5. Vendor Independence
The system generates high-precision spectrums from any sensor, removing dependency on third-party platforms and avoiding vendor lock-in
Looking Ahead
ACME plans to extend this platform to other services such as Thermography, offering clients a unified view of factory health and reinforcing their commitment to reliable operations.
