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Manufacturing & factory operations

IoT, sensors, and smart metering—from leak detection to OEE and ROI—software and telemetry that sharpen shop-floor decisions.

Refinery water network monitoring with flow KPIs and a piping schematic to factory lines and a cement plant.

On the shop floor, fragmented machine data, tacit maintenance know‑how, and supply delays hit at once. Stronger ties with overseas plants and subcontractors often deepen “factory‑specific quirks,” where uniform dashboards rarely align meaningful thresholds.

TokyoScale pairs proven metering hardware with cloud platforms and a shared definition of which losses matter financially and operationally.

What it looks like on site

Screens from real deployments—refinery water, warehouse metering, irrigation channels. Language and place names are localized per client.

Plant water network — flow and distribution

Refinery water monitoring with pump flow KPIs and a piping schematic to residential zones, factory lines, and a cement plant.
Pump flow totals (daily, monthly, yearly) and a piping schematic with per-branch meters to factory lines and a cement plant—shared by utilities, maintenance, and HSE teams.

Warehouse line — smart meters and gateways

IoT topology for a warehouse line showing smart meters, pressure gauges, gateways, and online status.
Warehouse-line instrumentation topology—meters, pressure gauges, gateways, and online/offline state. We design and validate per site before scaling to thousands of endpoints.

Process control — live flow and level

Control screen with per-channel level setpoints, flow in m³/s, and auto/manual operating modes.
Per-channel level setpoints, flow (m³/s), and auto/manual modes—abnormal definitions and escalation paths built into operator screens first.

Sensor commissioning — encoders and level meters

Encoder calibration for sluice gates and level-meter height, distance, and correction settings.
Encoder calibration and level-meter height, distance-to-water, and correction factors—turning tacit field know-how into repeatable commissioning screens.

Energy metering — site-wide electricity report

Multi-site electricity meter report with active and reactive energy deltas across plant departments.
Department-level three-phase meter readings—foundation for loss analysis with plant utilities teams and line-level anomaly detection.

Instrumentation partners

For water, power, and flow measurement on the plant floor:

  • Ningbo Water Meter — bulk ultrasonic meters, AMI/AMR, remote monitoring of abnormal usage for utilities and HSE teams
  • Shandong Rongxian Instrument — electromagnetic flow meters, prepaid three-phase electricity meters, combined flow and power monitoring on process lines
  • Ningbo Xingyuan Meter — single/multi-jet smart meters, M-Bus, industrial meter bodies and fittings
  • Yuhuan Sierjia Valve — motorized valves, remote shutoff, process-line flow control

Themes we emphasize

  • IoT / sensors / edge — vibration, temperature, flow, consumption: start from definitions of abnormal and escalation paths, not sensor catalogs.
  • Water, energy, material loss — smart metering for anomaly usage and leakage candidates—often landing well with ops, HSE, and finance together.
  • Offshore peers & contract factories — sync purpose of visibility with who can act when habits and systems diverge.
  • Beyond vanity OEE — mean time to recover, repeat incidents, queue time—signals that steer daily work.

How we collaborate

Engagements frequently involve equipment OEMs, instrumentation vendors, plant leadership, or group HQ—bridge‑building matters more than a flat feature backlog.

Example: integrated utility dashboards

Pump-station SCADA, a 7,000+ device MQTT registry, and gas regulation monitoring—one operational model.

→ Utility metering platform

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