The rapid evolution of Industrial IoT (IIoT) is quietly reshaping how global industries handle one of the most basic, yet critical, tasks: maintenance. In an age where every minute counts, remote diagnostics and maintenance have emerged as a game-changer for organisations looking to increase operational efficiency and reduce costs. From manufacturing units to healthcare facilities, IoT-powered remote monitoring is creating a new norm.
Fundamentally, remote diagnostics and maintenance work around a straightforward idea. Data is collected from equipment through sensors and connected devices, then analysed to identify irregularities or maintenance needs before they cause breakdowns. But the benefits of this process go far beyond early detection. It transforms maintenance from a reactive function into a proactive strategy, empowering operators and OEMs alike to:
- address problems before they escalate,
- improve equipment lifecycle management, and
- reduce technician intervention.
With fewer site visits required and shorter response times, the financial and operational impact is significant.
A McKinsey study notes that predictive maintenance doesn’t just lower maintenance costs by up to 25% but also lifts production line availability by as much as 15%.
There are primarily two ways these systems are introduced into operations: retrofit and factory-fit. Factory-fit solutions, being built into the product at the manufacturing stage, offer greater precision and compatibility. Retrofitting, on the other hand, puts modern monitoring capabilities into older machines. Although slightly less efficient, retrofitting is invaluable for facilities unable to replace legacy systems but still aiming to adopt smart maintenance practices. For many smaller or mixed-facility operations, combining both approaches may be the most cost-effective strategy.
In manufacturing environments, the role of IoT-enabled diagnostics is particularly prominent. Equipment in such settings is often complex, heavily used, and prone to wear and tear. Here, sensors monitor for performance anomalies, vibration changes, or heat levels to catch developing issues early.
Beyond factory floors, IoT-driven remote diagnostics are proving critical in hospitals and other healthcare centres. Medical facilities rely on uninterrupted performance from a vast array of machines, from MRI scanners to digital thermometers. Maintenance delays here can be dangerous, even fatal. With medical devices becoming more complex, and often managed by third-party service providers, constant monitoring is not just beneficial—it’s necessary. A strong example is Philips' e-Alerts system, which leverages IoT sensors to monitor vital signs of MRI machines. In doing so, it helps prevent technical failures and ensures diagnostic equipment functions smoothly, as lives depend on it.
Another promising use case lies in vertical transportation—systems like elevators and escalators that keep high-rise buildings functional. Their failure can create inconvenience at best and emergencies at worst. By embedding sensors to track equipment conditions in real time, maintenance teams can be alerted about potential malfunctions, and the frequency of routine manual inspections can be easily reduced. In an age of urbanisation, where buildings are only getting taller and more complex, IoT brings both convenience and safety to vertical transport management.
Remote diagnostics and maintenance, therefore, go far beyond fixing equipment. They form the backbone of a smart, connected operational model that anticipates needs, responds swiftly, and helps industries remain agile in competitive environments. The cost savings, service improvements, and risk reductions are not future promises—they are already being realised today.
However, to make the most of remote diagnostics is an art in itself. Businesses must:
- begin with a pilot—select one high-maintenance asset class, implement monitoring, and observe outcomes.
- ensure teams are trained to interpret data and act quickly on alerts.
- integrate with existing systems and define protocols for escalation.
Over time, insights from early deployments can guide wider rollouts, helping build a reliable, scalable model for digital manufacturing service support without disrupting ongoing operations.
Today, the question is no longer whether a business should invest in remote diagnostics or not, but how quickly one can implement it and integrate across functions. The industrial leaders who act now won’t just improve efficiency—they’ll redefine it.
how can Infosys BPM help?
Infosys BPM’s digital manufacturing service supports manufacturers in scaling operations through real-time monitoring, MES assistance, and streamlined plant maintenance. From improving shop floor productivity to reducing downtime, its solutions help manufacturers harness remote diagnostics more effectively. By integrating asset tracking, inventory control, and quality checks, Infosys BPM empowers clients to build smarter, scalable, and insight-led manufacturing environments.
