PlantWiz · Industrial Intelligence
Industrial Intelligence for Plants That Run on Data.
Your plant already has the sensors. The PLCs are already logging. The energy meters are already spinning. What you don’t have is one place where all of it becomes a decision — while the shift is still running, not after the month closes.
PlantWiz is Pima Controls’ industrial intelligence and industrial IoT platform, built for manufacturers anywhere in the world. Proven in demanding plant environments and engineered to run on the equipment you already own, it connects to your existing assets and turns machine data into decisions, wherever your plants operate.
What PlantWiz Actually Is
One Industrial IoT Platform. Five Intelligence Modules.
PlantWiz is Pima Controls’ IIoT platform for manufacturers who want real-time control of their operations. It connects to the machines you already run and brings OEE tracking, downtime analysis, predictive maintenance, vibration monitoring and energy intelligence into one live view. Whether you run one plant or many, PlantWiz turns shop-floor data into decisions that cut downtime, waste and cost.
Deploy one service line or all five. They share the same gateway, data layer and login.
Smart Manufacturing
OEE, downtime and capacity visibility.
Predictive Maintenance
AI/ML asset health and failure prediction.
Energy Intelligence
Machine-level energy and sustainability data.
Vision IQ
Safety, security and operations analytics.
Immersive Intelligence
AR/VR training and digital twins.
Why Choose PlantWiz
Why Plants Choose PlantWiz Over a Generic IIoT Stack
As one of the leading industrial IoT platforms built for India, PlantWiz is engineered around how Indian plants actually operate, not adapted from a Western product.
The Five PlantWiz Service Lines
Complete Industrial Intelligence.
Choose the capability your plant needs today and expand as your digital maturity grows.
Smart Manufacturing & Process Excellence — OEE Monitoring Software
Losses go unrecorded, data entry is manual, and downtime goes unmonitored. PlantWiz gives you a live view of every machine, automated KPI traceability, and actionable insights to reduce losses within the same shift.
Real-time OEE and MEE, calculated automatically
Downtime analysis with CAPA workflow
Capacity utilisation tracking
AI root-cause analysis on every downtime event
Auto-generated shift, daily and weekly reports
From a live packaging deployment: up to 13% less downtime, up to 18% more productivity, 100% accountability.
AI/ML Predictive Maintenance & Asset Health — Predictive Maintenance Software India
A critical machine can stop without warning, halting production and driving up emergency repair costs. PlantWiz AI learns each machine’s health pattern from triaxial vibration, temperature, and noise, warning you early enough to plan maintenance before failure.
Failure prediction 4–6 days ahead
60–80% fewer emergency repairs
Asset Health Score — 0 to 100 per machine, with full history
Automatic Diagnostics & Recommendations: fault type, risk level and the exact corrective action, written in maintenance language
Remaining Useful Life — days to warning, days to critical
From Indian manufacturing deployments: 2 of 3 typical failures prevented, 25–30% better equipment uptime, 9–12 months to ROI.
Energy Intelligence & Sustainability — Energy Monitoring System for Manufacturing
Most plants only learn what energy costs them after the month closes. PlantWiz shows which machine, shift, and process consumed energy while the shift is still running, helping teams identify waste and control costs in real time.
Electrical: kW, kVAR, kVA, power factor, voltage, current, THD and harmonics
Steam, compressed air, water, gas and solar generation against grid draw
Specific energy consumption per unit, tonne or batch
Energy cost per unit every shift
Idle waste where machines are running but not producing
Turn Every kWh Into Actionable Insight, Control Energy Waste, and Run Your Plant More Efficiently.
Vision IQ
99% of CCTV footage is never reviewed. Vision IQ turns your existing CCTV into real-time safety, security, and operational intelligence, detecting events and providing actionable alerts when they happen.
PPE and safety compliance detection
Intrusion and zone alerts
Fire and smoke detection
Cargo and dock intelligence
ANPR and vehicle intelligence
From enterprise Vision IQ deployments: 3,000+ cameras integrated, 85% fewer false alarms, 95% detection accuracy, 48 hours to go live.
Immersive Intelligence
Every training hour on the floor competes with production, while shadow-based learning can be slow and inconsistent. PlantWiz Immersive builds AR/VR modules from your own SOPs, drawings, and P&IDs, creating a digital twin of your actual equipment for practical, repeatable training.
VR Simulation Training — operators practise real procedures, fail safely, and repeat until the sequence becomes muscle memory
AR Field Assistance — instructions and highlighted parts overlaid on the actual machine
SOP to 3D Animation — written procedures turned into step-by-step animations
Safety & Emergency Simulators — fire response, evacuation, high-voltage work, working at height, and hazardous material handling
3D Plant Model & Layout — test layout and workflow changes before you spend
From Indian manufacturing deployments: 50% less training time, zero training incidents, and first module delivered in 4 weeks.
End-to-End Connectivity
How PlantWiz Connects to Your Plant
Field
Sensors, energy meters, ACBs and MCCBs on Modbus RS-485 loops; existing PLCs and cameras.
Control
Industrial gateways with communication modules. PlantWiz speaks the protocols your plant already runs on: Modbus TCP/IP and RTU, OPC-UA, MQTT, RS-485, EtherNet/IP, PROFINET, BACnet, REST API and WebSockets.
Network
Ethernet/IP backbone, fibre between panel rooms.
Server
On-premise, cloud or air-gapped. Your data, your choice.
Edge intelligence
Data quality is validated at the edge. FFT and anomaly models run there. Each machine’s own normal is learned locally, so the platform is not dependent on a permanent cloud connection.
EDGE Hardware
The PlantWiz PG-101 Edge Gateway
A plug-and-play edge gateway that takes you from PLC to cloud, wired or wireless. Made in India.
Fully programmable OpenWRT platform
Multiprotocol communication
Local data buffering for up to 15 days
Industrial-grade I/O and protection
Multiple connectivity options — MQTT, HTTP/HTTPS, API
Inbuilt RMS capability
The 15-day local buffer matters more than it sounds: when the plant's internet drops, data collection does not stop, and nothing is lost from the record.
Proven in Real Plants
Results From Live PlantWiz Deployments
- Automotive — energy monitoring system. Data-driven diagnostics, comprehensive engineering analysis and real-time monitoring across central utility and panel rooms, integrating Allen-Bradley PLCs over EtherNet/IP with energy meters and ACBs on Modbus loops.
- Manufacturing — real-time production visibility. 7% reduction in energy use, averaging 27 units saved per day. 15% improvement in production and operational time through better setup and idle-time management.
- Plastics — production and energy visibility. 4% reduction in energy use, averaging 62 units saved per month. 19% improvement in production and operational time.
- Automotive press shop — vibration-based predictive maintenance. A press line stoppage from unforeseen mechanical press failure costs production, reputation and delivery commitments. Within weeks of deployment, downtime on a critical press-shop asset dropped by 14 hours.
Machines integrated
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Data points processed a minute
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Assets monitored under predictive maintenance
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Vision uses cases developed & running
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Immersive modules simulated
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FAQ
Frequently Asked Questions
What is PlantWiz?
PlantWiz is an industrial intelligence platform and industrial IoT platform developed by Pima Controls Pvt. Ltd. for manufacturers in India. It covers five service lines — smart manufacturing and OEE monitoring software, AI/ML predictive maintenance, energy monitoring for manufacturing, video analytics and AR/VR immersive training — running on one edge-to-enterprise architecture.
Do we need to replace our existing PLCs, sensors or cameras?
No. PlantWiz is designed to run on your installed base. It reads from existing PLCs over Modbus, OPC-UA, EtherNet/IP and PROFINET, from energy meters on RS-485 loops, and from 95%+ of existing CCTV via ONVIF and RTSP.
How long does a PlantWiz deployment take?
Deployment is measured in weeks, not quarters. Vision IQ can go live on existing cameras within 48 hours. The first Immersive Intelligence module typically takes four weeks. Smart Manufacturing dashboards are live within days of connecting to your PLCs.
Can PlantWiz run without an internet connection?
Yes. PlantWiz can be deployed on-premise or fully air-gapped inside your OT network. The PG-101 gateway buffers data locally for up to 15 days, so collection continues through connectivity outages.
Does PlantWiz replace our SCADA or CMMS?
No. PlantWiz sits alongside SCADA, CMMS and BI systems. PlantWiz decides; your existing systems keep the record.
Which industries is PlantWiz built for?
Wire and cable, packaging, auto components, textiles, pharma and FMCG, food and beverage, plastics and rubber, engineering and OEM, cement, chemicals, steel and metals, power and utilities, logistics, oil and gas.
How do we start?
With one critical machine or one feeder. Book a plant assessment and we will show you what that machine has been trying to tell you.
Is PlantWiz available for manufacturers across India?
Yes. PlantWiz is deployed as a smart manufacturing software solution for manufacturers across India, from Gujarat and Western India to plants nationwide, as well as export-focused facilities internationally.
Still have questions?
Talk to our automation experts today.
See PlantWiz on your plant floor.
Bring us one critical machine. We’ll show you what it has been trying to tell you.
