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Manufacturing · Industrial IoT · Remote Asset Monitoring

How Spartan Engineering replaced on-site machine visits with remote AWS IoT monitoring

Spartan Engineering Industries is a Mumbai-based manufacturer and lessor of heavy construction machinery, in business since 1971. Its hoist machines ran on OEM-provided PLCs with no internet connectivity, so every maintenance check, breakdown, or basic troubleshooting call required an engineer to travel to the site. Flentas built an AWS IoT solution connecting each machine to the cloud, enabling remote monitoring, tracking, and troubleshooting without a site visit.

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Spartan Engineering40+ years in construction equipment manufacturingFleet of leased hoist machinesAWS IoT-based remote monitoring
At a Glance
5Remote operational capabilities enabled
ZeroSite visits needed for routine monitoring
4G/GSMConnectivity layer for real-time data and location tracking
The Challenge

Machines that couldn't be seen or reached remotely

Spartan's leased hoist machines were fully controllable through their onboard PLCs, but those PLCs were constrained devices with no path to the internet. Every routine check or fault meant sending an engineer to the site.

No usage visibility

Machine usage couldn't be tracked remotely, making metering and maintenance scheduling manual and reactive.

No sensor visibility

Critical sensor readings were only accessible on-site, delaying fault detection.

No asset tracking

Equipment location couldn't be monitored, leaving misplacement and misuse undetected.

The Approach

A gateway-to-cloud pipeline built for constrained devices

Flentas designed and implemented the end-to-end IoT solution in four layers: device connectivity, resilient data transport, cloud ingestion, and application integration.

  1. 01

    Deployed an IoT Gateway on each machine, pulling PLC register data over Modbus ASCII and connecting to AWS IoT Core via an integrated 4G module.

  2. 02

    Added GSM-based location tracking for asset movement, with SD-card data buffering on the gateway to handle downstream network issues.

  3. 03

    Used MQTT for downstream communication to AWS IoT Core, with a Pi Zero-based module handling gateway software deployment.

  4. 04

    Built the data pipeline from PLC → IoT Gateway → IoT Core → Kinesis → Database, exposed through REST APIs consumed by Spartan's existing O&M web and mobile applications.

Business Outcome

Remote visibility, faster response, fewer wasted trips

Remote

Secure operations, with critical machinery actuation possible without an on-site visit.

Simplified maintenance tracking through usage-based metering and job scheduling.

Efficient asset tracking

With stakeholders alerted to equipment misplacement or misuse.

Fraud detection process established

Using sensor data to flag warranty-void scenarios in false claims.

Faster on-ground response

With fault notifications routed directly to the operations team for quicker MTTR.

“There are very few players in the Industrial IoT space who understand ground level needs and solid solution capabilities on cloud. We were able to quickly integrate Flentas’ IoT Gateway with our construction Hoist PLC.”

Ganesh SahaniGM ITSpartan

Technologies & Partners

Built on the AWS IoT stack

AWS IoT CoreAmazon KinesisModbus ASCIIMQTTGSM-based location trackingPi Zero gateway moduleREST APIs
Common Questions

What manufacturers usually ask about this kind of IoT retrofit

Related

Where this fits

Get Started

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