Are concerns about the impact on your workforce holding you back from transitioning to a smart factory?  

Your maintenance team’s expertise has always been the backbone of your manufacturing equipment’s upkeep and longevity. But right now, many of them are watching artificial intelligence (AI) and machine learning (ML) transform their workplace and wondering where that leaves them. We get it, a recent surveys show 30% of workers fear technology might eliminate their roles within three years, while 39% worry they won’t get the training they need to keep up with all this change.  

First, it’s important to acknowledge the truth: Automation will reshape and eliminate some maintenance roles, just as technology has throughout history. However, history shows that it will also create new jobs and opportunities for teams eager to embrace digital transformation. Rather than resist this transformation, forward-thinking organizations are focusing on how to evolve their workforce alongside these technologies. 

Embedded intelligence and IIoT: Bringing power to the people 

For some maintenance professionals, the initial fear about smart factory transformation is about maintaining their sense of value and professional identity. While automation will eliminate many routine tasks, technology is transforming traditional “soft skills” like communication and teamwork into “power skills”, making these distinctly human capabilities more crucial in an AI-driven workplace. 

These skills include strategic thinking to prevent problems before they occur, ethical judgment to make tough calls about safety and resources, and the ability to communicate complex technical information clearly across teams.  

To thrive in IIoT-integrated manufacturing, maintenance professionals need to develop key technical capabilities that complement their power skills. These are skills like data literacy to interpret sensor readings and maintenance predictions, foundational knowledge of predictive machinery to understand when to trust or question automated recommendations, practical experience with digital twin technology for remote diagnostics and training, and a solid understanding of IoT systems to ensure reliable connectivity and accurate data collection. 

This upskilling requires commitment from both leadership and employees. Reports show that companies are planning to invest 9% of their collective reskilling efforts specifically in big data capabilities.  

Professionals need training that goes beyond just learning new software, they need opportunities to develop and practice their power skills. Let’s explore what’s possible when maintenance professionals develop their skills to operate on a smart factory floor.  

They become strategic decision-makers 

Remember when your maintenance team spent hours logging temperature readings and jotting down equipment data? Manual data entry used to consume maintenance professionals’ time, but in a smart factory, automation can handle those routine tasks. With IIoT integrated systems, IoT devices handle the manual work, streaming real-time data straight to your team’s dashboard. When IIoT devices collect better data more efficiently, your maintenance team can flex their expertise in entirely new ways. 

Picture this: your team gets an alert flagging temperature patterns outside the normal range in several motors. Instead of rushing to check each one manually, they’re now analyzing this data alongside vibration readings and power consumption trends. They’re applying their years of experience to decide which alerts need immediate attention and which ones they can monitor. 

This is where technical knowledge meets critical thinking skills in a way that intelligent machines alone can’t match. This powerful blend of technical insight and human judgment helps them make smarter decisions about when to schedule maintenance or simply adjust operations to extend equipment life. 

Their workplace becomes safer 

Making smarter decisions is important, but making safe decisions is essential. That’s where digital twin technology adds another powerful layer to your maintenance team’s capabilities. A digital twin is a virtual replica of a physical system, such as a machine, a process or even an entire factory. Using real-time sensor data, these digital replicas accurately mirror the current state, behavior and performance of their physical counterparts.  

Take the example of a chemical processing plant. When troubleshooting a problem with a high-temperature processing unit, instead of immediately suiting up to investigate an issue, maintenance professionals can now examine a detailed virtual replica of the equipment from every angle, analyze thermal sensor data, and pinpoint potential problems from a safe distance. When physical inspection is required, they’re empowered by precise data about what they’ll find and AI-validated predictions about equipment status. 

They grow their skills  

The educational potential of digital twin technology extends far beyond basic safety improvements. New technicians can now practice complex maintenance procedures in a virtual environment before touching physical equipment.  

For example, they might simulate the replacement of a critical pump component, using the digital twin to visualize internal parts and practice the procedure while receiving real-time feedback on their technique. This requires both technical proficiency with simulation software and problem-solving skills to handle unexpected scenarios that arise during training. 

Maintenance professionals can also use these tools to transfer their knowledge more effectively. For example, an experienced technician can use a digital twin to show new team members how equipment sounds indicate problems, using acoustic sensor data to visualize these subtle changes. This knowledge transfer helps newer team members develop both technical understanding and intuitive recognition of potential issues. 

They maximize the value of their work 

With predictive maintenance, your team are strategic partners in resource management. When an organization utilizes predictive maintenance, technicians combine real-time sensor data with their understanding of the equipment to make decisions about which equipment needs attention.  

While the system automatically checks inventory and can trigger parts orders, it’s your maintenance professionals who make the difference. They’re using their critical thinking skills to validate these automated decisions, considering things algorithms might miss, like that upcoming scheduled maintenance window or those equipment upgrades you’re planning next quarter.  

A traditional maintenance approach based on time-based service intervals might flag a bearing for replacement based purely on age, but your team’s analysis of the sensor data provided by intelligent devices shows it’s still performing perfectly. That’s saving unnecessary maintenance costs and shows how human expertise can work together with smart factories to keep your operation reliable and efficient. 

Empowering tomorrow’s maintenance team today 

As intelligent machines work in the background to automate routine tasks, they create new opportunities for skilled professionals who can combine their hands-on experience with data-driven insights to make better decisions about equipment health and maintenance timing.  

Digital transformation is about embracing a new mindset where human expertise and IIoT capabilities enhance each other. By achieving this vision, your maintenance team are industry leading. Connect with our team to begin your digital transformation journey. 

Additional Resources 

• Find out how Blues transformed American Crane’s operations 
• Download our guide to the sign’s your industrial equipment is ready for digital transformation 
• Get access to your devices data and fuel your factories AI processes 

The post IIoT Integration: How Digital Transformation Empowers Maintenance Professionals appeared first on Blues.

The ESP32 has become a go-to platform for engineers, makers, and businesses building connected devices. Its compelling combination of dual-core performance, integrated WiFi and Bluetooth, affordable price point, and rich GPIO options makes it ideal for rapid prototyping. However, for many teams, what begins as a promising proof of concept quickly encounters a familiar roadblock: reliable connectivity in real-world deployments. 

Cellular networks are global, reliable, and increasingly efficient data transmission. For ESP32 solutions venturing beyond controlled environments, cellular should be the natural evolution. Yet for many organizations, integrating cellular connectivity has historically been more trouble than it’s worth. 

Why does cellular integration have to be so complex? And what would seamless ESP32 cellular connectivity actually look like? 

Why ESP32 + Cellular is a Winning Combination 

The popularity of the ESP32 isn’t hard to understand. It balances power, cost, and flexibility, with dual-core performance, integrated radios, and support for familiar development frameworks like Arduino and ESP-IDF. Making the ESP32 the top choice for everything from custom hardware startups to Fortune 500 R&D teams. 

However, WiFi and Bluetooth Low Energy excel primarily in controlled environments. Once you move beyond the lab, their limitations become apparent. Many IoT deployments require connectivity in challenging locations: agricultural fields, oil rigs, power stations, cargo trucks, and remote monitoring sites. These environments rarely offer reliable local networks or consistent power infrastructure. 

Cellular connectivity directly addresses these challenges. It provides: 

• Global coverage: Operate across countries and continents without infrastructure dependencies 
• Carrier-grade reliability: Benefit from decades of telecommunications infrastructure investment 
• Rural and urban reach: Access data in locations where WiFi simply isn’t available 
• Predictable performance: Leverage standardized protocols and service level agreements 

Pairing of ESP32 with cellular connectivity offers an ideal solution: an affordable, low-power compute platform with always-on global data access. In practice, however, this is where complexity traditionally begins. 

What’s Historically Made Cellular So Difficult? 

While cellular may solve the connectivity challenge, it often creates new ones. For product and engineering teams, integrating cellular can come with unexpected delays, hidden costs, and architectural complexity that slows down even the most agile development cycles. 

It usually starts with the modem. Most cellular modules require working directly with AT commands, a decades-old interface language that’s unintuitive, inconsistent across vendors, and painful to debug. Writing and maintaining firmware to handle modem state, retries, error handling, and power management can quickly consume weeks of engineering time. 

Next, you need to provision your fleet. Carrier contracts, SIM management, region-specific data plans, and compliance requirements vary widely depending on where you plan to deploy. Testing in one geography doesn’t guarantee performance in another which makes managing fleets of devices across carriers a logistical headache. 

Power consumption is another common concern for devices that are deployed remotely. Cellular radios draw significantly more power than WiFi or BLE modules. For battery-powered products, a poorly integrated modem can cut device life from months to days. 

And finally, there’s the cloud platform where you gain access to your data. Piping data from device to cloud requires a reliable and secure data flow. You’ll need to manage encryption, message queuing, device identity, and remote updates, all before you ever see a byte of data. 

For teams working on time-sensitive roadmaps or operating with lean technical resources, this traditional approach is often a non-starter. 

A Smarter Path to Cellular-Enabled ESP32 Deployments 

What if cellular integration didn’t require navigating modem commands, carrier relationships, and custom firmware development? 

This is where Blues transforms the equation. Our plug-and-play cellular solution is purpose-built for platforms like the ESP32, handling everything from SIM provisioning to cloud data routing. This allows your team to focus on delivering product value rather than building connectivity infrastructure. 

Modern cellular integration for ESP32 should provide: 

• Seamless Development Integration: Drop-in compatibility with Arduino IDE and familiar APIs that abstract cellular complexity while maintaining control over device behavior. 
• Global Connectivity Out-of-the-Box: Built-in SIM and worldwide data plans that eliminate carrier negotiations and regional deployment complications. 
• Intelligent Power Management: Hardware and software designed for battery-powered applications, with automatic sleep/wake cycles that extend device life without compromising connectivity. 
• Secure Cloud Routing: Encrypted data transmission to your preferred cloud platform without requiring additional networking stack development. 
• Fleet Management Capabilities: Over-the-air updates, remote configuration, and device monitoring that scales from prototype to production deployment. 

For product managers and engineering leaders, the business value of using a ready-made cellular solution is clear: faster time to market, reduced development risk, and predictable deployment costs.  

With Blues there are no AT commands, no vendor lock-in, just a straightforward path from prototype to production. 

It’s Time to Rethink Cellular for ESP32 

If you’re building connected devices on the ESP32 and plan to deploy beyond controlled environments, cellular should be a strategic priority. But that doesn’t mean you need to accept the pain that traditionally comes with it. 

Modern cellular solutions designed for embedded systems are changing the development landscape. By abstracting complexity and offering predictable performance, Blues allows your team to focus on what matters: delivering value, moving fast, and scaling with confidence. 

Whether you’re launching a new product or evolving an existing one, choosing the right connectivity path can mean the difference between a stalled prototype and a deployed solution. Ready to transform your ESP32 products from WiFi limited to globally connected? Contact our team to see how Blues can accelerate your product development. 

Additional Resources 

• Get started with Blues development kits 
• Explore technical documentation for getting started with Blues
• Download our guide: Build or Buy: The True Cost of Developing Wireless Connected Devices 

The post From WiFi Limitations to Global Connectivity: How Blues Simplifies Cellular IoT for Your ESP32 Products appeared first on Blues.

That’s exactly what Lift AI accomplished when they remotely transformed their nationwide elevator management platform. Lift AI operates devices installed in elevator shafts, continuously monitors performance and detects anomalies to enable predictive maintenance for building owners and maintenance companies. 

When Lift AI needed to completely replace the firmware stack on thousands of deployed devices, transforming them from CircuitPython-based systems to production-grade Zephyr RTOS, they turned to Croxel for what would become a remote “brain transplant” for their fleet. 

Croxel, a Blues-accredited partner, specializes in complex embedded systems transformations, particularly in scenarios where traditional approaches fall short. They focus on architectural migrations that require deep technical expertise, making them the perfect partner to help Lift AI transform its devices. 

The Challenge: Complete Platform Transformation at Scale 

What happens when “it’s not you, it’s me” becomes “it’s not me, it’s the entire technology stack”? Lift AI’s original CircuitPython-based platform had served them well during rapid development and deployment phases. However, as their fleet grew and customer demands evolved, they needed a more robust, scalable foundation. The goal was to transition to Zephyr RTOS for improved performance, enhanced power efficiency, and deterministic operation. 

The constraints were significant: Lift AI has devices installed in active elevator shafts, getting physical access would disrupt the service of those elevators and be expensive. Since elevator monitoring is critical for safety and maintenance, the transformation had to occur without interrupting data flow from these devices. 

This wasn’t a typical firmware update. It required replacing the entire technology stack, the runtime environment, memory architecture, hardware interfaces, and communication protocols, all while maintaining compatibility with existing cloud infrastructure. 

Future Proof Hardware Design: Blues Notecard 

Sometimes the best decisions are the ones you don’t know you’re making. Lift AI had integrated Blues Notecards into their devices, an intelligent connectivity module that provided the infrastructure needed for the remote transformation: 

• Secure cellular connectivity for delivering the new firmware 
• Independent operation from the host processor, creating an air gap 
• Maintained communication throughout the transition 
• Automatic failover capabilities if issues arose 

“We chose Blues early on because we knew connectivity would be critical, but we never imagined it would enable us to completely transform our platform remotely,” said Rob Wurth, CEO of Lift AI. “Being able to do a full remote brain transplant of all of our devices saved us countless dollars in new hardware as well as the engineering time it would have taken to physically replace every device.” 

Finding the Right Partner: Croxel’s Specialized Expertise 

Lift AI successfully deployed their fleet of devices that utilized Blues Notecards. Here’s where Croxel came in to provide experience with CircuitPython, Zephyr RTOS, Blues and building critical systems that made the transformation possible. 

Working with a partner gave Lift AI access to technical expertise they didn’t have and reduced the risk of experiencing common pitfalls. Allowing Lift AI to focus on their core business of elevator management. 

Albert Garvett, CEO and Co-Founder at Croxel shared, “When Lift AI approached us with this unprecedented challenge, they weren’t just looking for firmware developers. They needed partners who could envision and execute what many would consider impossible.’”

Here’s what Croxel enabled for the Lift AI fleet:  

• Every device in Lift AI’s fleet successfully migrated to Zephyr RTOS remotely 
• Zero downtime during the transition 
• Enhanced platform capabilities including improved response times and power efficiency 
• Hundreds of thousands of dollars saved by avoiding technician visits 
• Future-proofed architecture ready for continued evolution 

Redefining Fleet Management 

Lift AI and Croxel demonstrate that IoT devices in the field aren’t locked into their original technology choices. By choosing future-proof foundational technologies, even fundamental architectural changes can be deployed remotely. 

Here’s some additional benefits of remote fleet management: 

• Investment Protection: IoT companies make a significant investment in physical hardware, provisioning and deploying devices to the field. Instead of replacement, this hardware’s lifespan can be extended through platform evolution. 
• Technology Adaptation: Technology is evolving rapidly, as are regulations around connected devices. Companies who can update their devices remotely can remain cutting edge, competitive and compliant. 
• Operational Efficiency: Remote transformation capabilities reduce the risks and costs associated with physically swapping out your devices, including the cost of downtime.  

This represents a shift from viewing connectivity as an endpoint to treating it as one component of an intelligent system that can evolve over time. 

The Future is Transformable 

The project establishes a new paradigm: Smart fleets that can fundamentally transform without physical intervention. Companies that understand this capability can adapt to technological changes faster than competitors locked into static platforms. 

Ready to explore remote fleet transformation? Join our Fireside Chat with the team at Croxel, where we will discuss how they transformed Lift AI’s fleet without touching any hardware, on Wednesday, August 6th at 1 PM ET / 6 PM BST. 

The session will cover how Blues Notecard enables platform evolution, security essentials for remote updates, and strategies for maximizing hardware investments. 

Register now to learn the approach that made Lift AI’s transformation possible. 

The post Protect Your Hardware Investment: How Lift AI Remotely Transformed Their Platform with Blues and Croxel appeared first on Blues.

Understanding Location Technologies for IoT

When it comes to knowing “where in the world” your devices are, manufacturers aren’t settling for just one answer to the question. Here are three options for determining device location:

• GPS/GNSS: Provides global coverage with high accuracy in outdoor environments
• Cell Tower Triangulation: Works by measuring signals from multiple cellular towers
• WiFi Triangulation: Uses nearby WiFi access points to calculate position

Each approach has distinct advantages and limitations that make them better suited for different use cases and environments.

GPS/GNSS: Global Satellite Positioning

GPS (Global Positioning System) and other GNSS (Global Navigation Satellite Systems) determine location by measuring the time it takes for signals to travel from multiple satellites to the receiver:

• The device receives signals from four or more orbiting satellites
• Each satellite transmits its precise location and the exact time the signal was sent
• The receiver calculates the distance to each satellite based on signal travel time
• The device’s position is determined by triangulating these distances

This approach provides global coverage and works without relying on local infrastructure, making it ideal for outdoor tracking applications, despite limitations requiring line of site to satellites.

Cell Tower Triangulation: Leveraging Cellular Networks

Cell tower triangulation uses data from multiple cellular towers to pinpoint a device’s location:

• The device connects to or detects signals from nearby cell towers
• Signal strength and tower location data are collected
• Algorithms process this information to calculate the device’s position
• The estimated location is derived from the intersection points of coverage areas

While a single tower connection can provide rough location data that can be accurate within several hundred meters, connecting to multiple towers significantly improves accuracy, offering the potential to estimate device location within tens of meters.

WiFi Triangulation: Precision for Indoor Environments

WiFi triangulation is similar to cell tower triangulation but works by leveraging WiFi access points:

• The device scans for nearby WiFi access points
• Information about visible access points (SSID, MAC address, signal strength) is collected
• This data is cross-referenced against databases of known WiFi locations
• A precise location estimate is calculated based on this information

WiFi triangulation often delivers superior accuracy in urban and indoor environments and can easily achieve accuracy within a few meters. This makes it particularly valuable for indoor asset tracking.

The Business Value of Multi-Technology Asset Tracking

Why settle for just one tracking technology? Modern IoT deployments benefit from having multiple location-determining technologies available. Implementing a flexible location tracking approach offers several advantages:

• Improved Reliability – By combining multiple location technologies, devices can be located from open outdoor spaces to building interiors and urban canyons, ensuring continuous visibility.
• Optimized Power Management – Different location technologies can be selected based on power availability and accuracy requirements:
• GPS for high-precision outdoor tracking when power is available
• WiFi triangulation for indoor tracking with minimal power consumption
• Cell tower triangulation as a reliable backup when other methods aren’t available
• Extended Device Lifespan – Selecting location technology based on environment and power constraints can significantly extend battery life and reducing maintenance costs.

Blues Notecard: Simplifying Location Tracking

Blues Notecard is designed to make wireless connectivity for embedded devices as simple as plug-and-play. Cellular Notecards come with GPS tracking as standard and, depending on which connectivity solution you choose for your device, offers a combination of triangulation technologies.

Notecard Cell+WiFi gives you a seamless way to do all three, GPS tracking, WiFi triangulation, and cell-tower triangulation, in a highly customizable way. And Notecard’s backing cloud service, Notehub, intelligently selects the “best” location from all available options; making it easy to keep track of where your devices are at all times. Whether your assets move through dense urban centers or remote areas with spotty coverage, this hybrid technology ensures continuous location visibility across all deployment scenarios.

Real-World Location Tracking Applications

Wondering how you could use location tracking to enhance your operation? Here are a few of the ways you could utilize Notecards’ built-in features:

Supply Chain & Logistics

Track shipments through warehouses, distribution centers, and retail locations where GPS signals are unavailable. With triangulation, companies gain end-to-end visibility into their supply chains, including indoor locations traditionally considered “blind spots.”

Industrial Equipment Monitoring

Monitor the location and usage of valuable equipment inside factories and warehouses without installing dedicated positioning infrastructure. The low-power requirements make tracking assets for years without battery replacement possible.

Smart Cities & Urban Monitoring

Deploy sensors throughout urban environments to monitor air quality, noise levels, traffic patterns, and more, all with precise location data even in challenging signal environments between tall buildings.

Healthcare Asset Management

Track critical medical equipment throughout healthcare facilities, ensuring that life-saving devices can be quickly located while reducing equipment loss.

The future of Location Tracking

As IoT deployments expand into increasingly challenging environments, having multiple location technologies available ensures continuous device visibility across all scenarios. By leveraging GPS, cellular, and WiFi triangulation as complementary technologies, solutions like the Blues Notecard enable comprehensive asset tracking with optimal power consumption and accuracy for each environment.

Whether you’re tracking assets through supply chains, monitoring equipment in industrial facilities, or deploying smart city sensors, the flexibility to choose the right location technology for each situation provides the reliability and accuracy your IoT applications demand, in any environment.

Are you ready to implement intelligent location tracking in your IoT solution? Notecard offers a plug-and-play approach that simplifies development while providing the security, reliability, and power efficiency required for real-world IoT deployments. Get in touch to hear more.

Additional Resources

• Get started with a Cell+WiFi Dev Kit 
• Download the guide to learn more about industrial equipment monitoring 
• Try an example app for continuous asset tracking 

The post Beyond GPS: Leveraging Cell + WiFi Triangulation for Precise IoT Location Tracking appeared first on Blues.

However, the true value of IIoT lies in its ability to scale—connecting thousands, or even millions, of devices to drive automation, monitor assets, and make data-driven decisions. But scaling isn’t just about adding more devices. It’s about ensuring your system remains efficient, secure, and manageable as it grows. 

Without a plan for scaling, what works in a controlled environment can break down in the real world. Network bottlenecks, power inefficiencies, and outdated firmware can turn a promising deployment into a costly headache. That’s why it’s critical to design systems with scalability in mind—from choosing the right hardware and connectivity solution to ensuring robust device management and data handling strategies. 

The Challenge of Building Scalable IIoT 

We know that building hardware is…well, hard! Device manufacturers face several challenges when designing scalable IoT products. These challenges span hardware, software, network infrastructure, and long-term device management. Some of the key obstacles include: 

• Power Constraints: Devices must operate efficiently, especially in remote or battery-powered setups, requiring low-power components and optimized energy use to extend lifespan. 
• Bandwidth Bottlenecks: Scaling IoT increases data traffic; managing it requires prioritizing critical information, compressing data, and optimizing transmissions to avoid congestion. 
• Interoperability: Embedded systems must work seamlessly across radio access technologies like Cellular, WiFi, Satellite and LoRa, ensuring connectivity no matter where your device is deployed without needing to alter your firmware. 
• Signal Reliability: Maintaining stable connections in environments with interference or weak signals requires adaptive antennas, redundancy, and error correction. 
• Over-the-Air Updates: Securely deliver firmware updates remotely, ensuring all devices stay current without physical intervention or downtime. 
• Data Overload: Handle the massive data generated at scale by using real-time processing to filter, aggregate, and analyze critical information effectively. 
• Real-Time Processing: Ensure quick, reliable data exchange for time-sensitive processes by leveraging edge computing and low-latency networks. 
• Securing at Scale: Implement robust encryption and authentication measures that scale efficiently across thousands or millions of devices. 
• Device Monitoring and Maintenance: Track device health, battery life, and connectivity to proactively address issues and minimize downtime in large-scale deployments. 

Introducing Notecard and Notehub 

Designing scalable technology doesn’t have to mean costly upgrades to your equipment’s hardware, in fact Notecard is designed to fit in with what you’ve already built.  

Notecard combines out-of-the-box wireless connectivity, low-power design, and market-leading security into a System-on-Module which enables you to connect your product to the cloud using the full spectrum of radio access technologies including cellular, Wi-Fi, satellite and LoRa, within an interchangeable architecture. Notecard works together with Notehub, your command-and-control center for effortless, streamlining provisioning, and remote device management.  

How Blues Enables Scalable IIoT 

Scaling IoT deployments isn’t just about adding more devices; it’s about empowering those devices to operate seamlessly and deliver value in real time. Here’s how our solutions enable you to build smarter, more scalable systems: 

• Remote oversight – With Notehub, you gain full visibility and control of your devices from any location. Real-time monitoring helps you stay ahead of potential problems by flagging unusual patterns early on, so you can address them before they impact your system.
• Actionable Intelligence – Data is power—but only if you can turn it into actionable insights. Notecard transmits critical data securely to Notehub, from there, you can send your data to any cloud platform. Use data to improve operations, enhance products, and make informed decisions, and use machine learning to make predictions about the future behavior of your devices.
• Over-the-air updates – Through Notehub, deliver over-the-air updates to your devices to roll out new features or security patches remotely. Be sure every device is kept up-to-date, without the need for any physical intervention which reduces operational overhead.
• Generate recurring revenue – Access to real-time device data not only adds value for your customers but also creates opportunities for recurring revenue through offering access to all their systems across multiple locations from a single view to your customers as a subscription.
• Flexible Wireless Connectivity – Industrial environments are constantly evolving, and reliable connectivity is crucial. At Blues we provide flexibility by supporting multiple radio access technologies including cellular, WiFi, Satellite and LoRa. This adaptability ensures your devices stay connected regardless of location or changes in network requirements.
• Real-time Optimization – Real-time data is essential for responsive, efficient manufacturing. Our wireless device to cloud data pump gives you access to your data at intervals which you set, allowing you to see trends and make adjustments as they happen, optimize production flows, and make timely decisions to keep everything running smoothly. 

Build a Scalable Future with Blues 

By integrating Notecard and Notehub, you can transform your physical devices into data-driven intelligent machines and unlock a powerful set of tools that elevate your factory’s performance and capabilities. With features like remote oversight, actionable intelligence, and over-the-air updates, you’re set to unlock new revenue streams and make smarter, faster decisions that drive efficiency and value. 

Additional Resources 

• 5 Signs Your Industrial Equipment is Ready for IIoT Transformation  

• Navigating Network Sunsets: Future-Proofing Your IIoT Devices with Blues 

• Using IIoT to Navigate the Next Industrial Revolution with Sento and Blues

The post Scalable IIoT Simplified: How Blues Supports Manufacturers appeared first on Blues.

The market signals are impossible to ignore. In 2023, the global EaaS market hit $1.5 billion, and it’s not slowing down—we’re looking at 50% year-over-year growth through 2030. But what’s really driving this shift? In this blog we’ll explore how a desire to change your business model can signal your organization is poised to join the embedded intelligence revolution. Let’s dive in. 

Your Customers Want More than Just Hardware 

Consider this striking reality: industrial manufacturers lose $50 billion annually to unplanned maintenance. When customers buy equipment outright, they’re taking on all the risk. If they’re not getting optimal performance or if something breaks, it’s their problem.  

Your customers are feeling this impact directly, and they’re looking for partners who can help them solve it—not just sell them more equipment. But what if you could change that equation? 

Three ways EaaS transforms your business

1. Predictable Revenue (That Your CFO will Love)

Instead of riding the roller coaster of one-time sales, imagine having steady, predictable revenue flowing in month after month. That’s what happens when you shift to usage-based or outcome-based pricing. Your customers get more predictable expenses, and you get more predictable revenue. Win-win.

2. Turn Data into Value

When your equipment is connected and monitoring performance 24/7, you can spot problems before they become disasters. Deloitte found that predictive maintenance reduces equipment breakdowns by 70% and cuts maintenance costs by 25%. That’s the kind of value that turns customers into advocates.

3. Become a Strategic Partner

This is about more than just changing your pricing model. When you’re delivering ongoing value instead of just equipment, you become part of your customer’s strategic planning. You’re no longer just the vendor they call when something breaks—you’re the partner helping them optimize their operations. 

Making the Change to EaaS: What You Need 

Successfully transitioning to EaaS means adding sensors to your equipment and ensuring they have reliable connectivity so you can access the equipment’s data. Let’s break down the essential components you’ll need to make this transformation work: 

Reliable Remote Monitoring 

Your equipment needs to consistently capture and transmit performance data. This means integrating sensors and monitoring systems that can track critical metrics like operational status, performance parameters, and early warning signs of potential issues. For example, in manufacturing equipment, this might include monitoring vibration patterns, temperature variations, and cycle times to predict maintenance needs before failures occur. 

Secure Cloud Connectivity 

Security is non-negotiable when it comes to industrial IoT. Your system needs end-to-end encryption and secure key storage to protect sensitive operational data. Modern IIoT solutions are incorporating sophisticated security features like STSAFE Secure Element with ECC NIST P-384 curve encryption, ensuring your data and devices remain protected from device to cloud. 

Flexible Deployment Options 

Every customer’s environment is unique. You need connectivity solutions that can adapt to different scenarios – whether that’s cellular for remote locations, WiFi for facility-based deployments, or LoRa for battery-powered applications. The key is having the flexibility to choose the right technology for each specific use case without being locked into a single option. 

Scalable Data Management 

As your fleet grows, you’ll need a robust system to manage all the incoming data. This includes: 

• Real-time data processing and analysis 

• Automated alerts and notifications 

• Historical data storage and trending 

• Integration with existing business systems 

• Fleet-wide device management capabilities 

Remember, successful EaaS implementation is about more than technology—it’s about creating a complete solution that delivers real value to your customers while being manageable for your team. 

Why now is the time 

The industrial IoT train is accelerating—analysts predict investments will blast past $1 trillion by 2026. Your competitors are probably already thinking about how to transform their businesses to keep up with Industry 4.0. The question is: will you lead or follow? 

Additional Resources 

Download our comprehensive guide 5 Signs Your Industrial Equipment is Ready for IoT Transformation to learn if you’re ready for IIoT transformation and how other Manufacturers are building new revenue streams with embedded intelligence. 

• Navigating Network Sunsets: Future Proofing your IIoT Devices with Blues 

• Fueling the Future of AI with Optimized Data Streams 

• AI-Powered Predictive Maintenance: Transform your industrial operations with Blues and Industrie Intelligente 

The post From One-Time Sales to Ongoing Success: The Manufacturer’s Guide to Equipment-as-a-Service appeared first on Blues.

So how can HVAC and heat pump manufacturers adapt to meet these evolving demands? In this article, we explore how making the shift to smart HVAC and heat pump units can provide a competitive edge and secure your business’s future success. 

The Evolving Landscape of the HVAC and Heat Pump industry  

The HVAC and heat pump industry is undergoing a significant transformation. Gone are the days when conventional, inefficient units sufficed. Today’s market dynamics are forcing manufacturers to do their part to create a more sustainable world. 

Modern consumers are no longer satisfied with basic functionalities; they demand adaptive, energy-efficient systems that integrate seamlessly into their digital lives. Energy efficiency has shifted from a perk to a prerequisite, driven by escalating energy costs and growing environmental consciousness.

In a world of smart homes, consumers expect HVAC and heat pump systems to offer  remote control, real-time alerts, and compatibility with other smart devices. Manufacturers clinging to outdated methods risk being left behind. Those who adapt to these evolving demands, however, position themselves as industry pioneers prepared to guide the sector into its next chapter. 

Why Going Smart is the Competitive Edge Manufacturers Need 

For HVAC and heat pump manufacturers, the way to future-proof their business is clear — integrate data-driven embedded intelligence into their appliances. Here are four reasons why embracing the smart route can elevate a manufacturer’s market position: 

• Operational intelligence: Modern HVAC and heat pump systems equipped with sensors and real-time data analysis capabilities can automatically adapt to changing environmental conditions. For instance, a system can adjust its output based on current room occupancy or the outside temperature, ensuring optimal performance and user comfort. 

• Proactive maintenance features: One of the standout features of smart systems is their ability to foresee potential issues. By analyzing data trends and system performance, they can predict when a component might fail or when maintenance is due. This not only extends the product’s lifespan but also saves consumers from unexpected repair costs. 

• Empowering consumers with control: The modern consumer wants to be in the driver’s seat. Integrating user-friendly interfaces and remote management features allows manufacturers to offer products that allow users to control their HVAC and heat pump systems from anywhere, set schedules, and even integrate with other smart home devices. This degree of control and customization is a significant selling point.

• Optimized energy efficiency: As concerns about the environment and energy costs grow, energy efficiency becomes a priority for consumers. Smart HVAC and heat pump systems are designed to operate at peak efficiency, adjusting in real time to minimize energy waste. This resonates with environmentally conscious consumers and also promises tangible savings on energy bills for your customers. 

Incorporating these smart features is about anticipating the future. As technology continues to advance, the gap between traditional and smart systems will widen. Manufacturers that invest in smart technologies now will be better positioned to lead the industry tomorrow. 

The Business Case for Smart HVAC and Heat Pump Systems 

In manufacturing, decisions are often driven by concrete figures and a clear return on investment (ROI). As the allure of smart HVAC and heat pump systems becomes evident, it’s essential to understand the tangible business benefits of this transition. Beyond meeting immediate market demands, integrating smart technologies is a strategic move to future-proof your business in a rapidly evolving industry. 

Reducing warranty claims: Smart systems, with predictive maintenance capabilities, can significantly reduce component failures and unforeseen system breakdowns. This translates to fewer warranty claims, which directly impacts a manufacturer’s bottom line by reducing the costs associated with replacements and repairs. 

Building brand trust: Offering cutting-edge, energy-efficient, and reliable products naturally boosts a brand’s reputation. Consumers tend to gravitate towards manufacturers they perceive as forward-thinking and committed to delivering the best possible solutions. This brand trust is invaluable in fostering loyalty and securing repeat business. 

Catering to a broader market segment: As homeowners and businesses increasingly prioritize sustainability and tech integration, manufacturers with smart offerings can tap into this growing segment. Additionally, by aligning products with current market trends, manufacturers can ensure their offerings remain relevant and in demand. 

Higher product margins: Premium features command premium pricing. Smart systems, given their advanced capabilities, can be positioned at a higher price point, leading to improved profit margins. Furthermore, as the demand for these systems grows, economies of scale can further boost profitability. 

Industry leadership: Manufacturers that embrace smart technologies set new industry standards. By pushing the boundaries of what HVAC and heat pump systems can achieve, these manufacturers position themselves at the forefront of the industry. This leadership status leads to increased market share and long-term profitability.  

A New Era of Intelligent Climate Control  

As consumer demand shifts towards intelligent, energy-efficient, and interconnected systems, manufacturers must adapt to stay relevant and competitive. 

Early adoption in this transformative phase is a market imperative. Those who move swiftly to integrate smart technologies into their product lines will position themselves as industry frontrunners, capturing a larger market share and future-proofing their business models with a competitive edge. 

Embracing this change is not a journey manufacturers have to embark on alone. With Blues, manufacturers gain a robust ally, ensuring a smooth, cost-effective transition into the future of smart HVAC and heat pump systems.  

Additional Resources 

• Download our guide to building a connected HVAC and Heat Pump System 

• Learn how wireless harmonization makes it effortless to connect your products to the cloud 

• Using IIoT to navigate the next industrial revolution 

The post Future-Proofing HVAC and Heat Pump Manufacturing: The Shift to Smart Systems appeared first on Blues.

For manufacturers of IIoT (Industrial Internet of Things) devices, network sunsets can be costly. When cellular carriers phase out older networks, manufacturers can find themselves facing expensive hardware redesigns to maintain compatibility. Today, we’re exploring how to harmonize your product development with evolving network technologies to protect your engineering investment and deliver seamless experiences for your customers. 

Understanding Network Sunsets 

Network sunsets occur when cellular carriers shut down older network technologies. This frees up spectrum for newer, more efficient networks. Common reasons include: 

• Advancing technology (e.g. 5G replacing 4G) 

• Reallocating spectrum to increase network capacity 

• Reducing costs of maintaining legacy networks 

As cellular carriers phase out older networks to make way for new technologies, manufacturers must redesign their hardware to support newer protocols—a process that can take months of engineering time and significant capital investment. 

The sunset of 2G and 3G systems continues to send aftershocks. A few European cellular carriers stopped supporting these connections in 2021 with U.S. carriers following suit in 2022, and the majority of European carriers plan to decommission 2G and 3G connections in 2025. If not addressed, mission-critical systems will lose their connection, leaving your business to foot the bill to replace or upgrade your IIoT hardware.  

The Product Design Challenge 

For device manufacturers, there’s a fundamental mismatch between product design cycles and network evolution. Your team designs industrial equipment for long-term operation, while cellular networks change approximately every decade. 

For example, when developing products for industries like agriculture, where equipment typically operates for 10-15 years, manufacturers must consider how to maintain connectivity as networks evolve. Traditional approaches often require complete hardware redesigns to support new protocols—a costly and time-consuming process. 

Future-Proofing Your IIoT Devices  

Advances in network technology don’t have to mean costly upgrades to your equipment’s hardware. At Blues, we’re leading the industry in developing wireless connectivity for smart manufacturing. When American Crane & Equipment Corporation wanted to future-proof its IIoT equipment, it turned to Blues to ensure consistent network connectivity.  

“We expect a 10X factor in cost savings for our smart crane system,” said Karen Norheim, ACECO President and CEO. “Through innovation in transmitting data, using the Blues system will provide lower up-front and ongoing costs than a traditional system.” 

Solutions for Every Connectivity Challenge 

At Blues, we understand the engineering and cost implications of network sunsets. That’s why we’ve developed flexible solutions that help manufacturers future-proof their products while minimizing redesign costs. 

Challenge: Your IIoT devices rely on a single connectivity source 

Solution: Your IIoT equipment is vulnerable to a network sunset if it only supports one connectivity option. Blues Notecards feature interchangeable radio access technologies that combine prepaid cellular connectivity, low-power design, and secure “off-the-internet” communications in one System-on-Module. These devices support multiple connectivity options including cellular, WiFi, LoRa, and Satellite connections. If one system becomes obsolete in the future, you have the flexibility to switch with minimal changes to your equipment’s hardware or software. 

Challenge: Upgrading IIoT Hardware is Expensive and Time-Consuming 

Solution: Notecard is designed with upgrade features that can be executed in the field, saving your organization time and resources. They’re also designed to be swapped out without redesigning host hardware. Blues also offers OTA updates for Notecards and host firmware, meaning you’re able to adapt your network tech without replacing entire devices.  

Challenge: Your IIoT systems rely on different connectivity sources. 

Solution: At Blues, we’re pioneering wireless harmonization. We empower our customers to seamlessly apply a single connectivity solution to multiple technologies with minimal design or software changes. Our products use a consistent API across all connectivity types, simplifying development and maintenance of your infrastructure as you adapt to network changes.  

Challenge: Your systems are tied to specific carriers and your coverage is inconsistent globally.  

Solution: With Notecard’s embedded Sim, you get global cellular connectivity coverage in over 135 countries worldwide. For areas without coverage, you are able to use an external sim alongside the Notecard to ensure global coverage, giving you flexibility to choose the best available network as the wireless landscape shifts. 

Challenge: Your organization needs long-term cost and operational stability 

Solution: Cellular carriers continue to evolve their networks faster than the lifespan of most IIoT devices, creating a heavy and unpredictable burden for businesses. We provide our customers with 10 years of service and use a pre-paid data model that eliminates ongoing costs. Plus, our global coverage solutions give peace of mind against short-term network changes disrupting your devices. 

Building for Tomorrow’s Networks Today  

Network sunsets don’t have to pose a threat to your business. Blues offers flexible, upgradable products and features to harmonize your industrial IoT infrastructure including:   

• Interchangeable connectivity options 

• Easy field upgrades 

• Consistent development experience 

• Carrier-agnostic global coverage 

• Long-term connectivity assurance 

• Extended device lifespans 

Ready to learn how Blues can help future-proof the IIoT technology your business relies on? Contact us today to get started. 

Additional Resources 

• How American Crane & Equipment Corporation is Cutting Cost by 10x for Their Smart Crane Technology 

• Blues: Fueling IIoT Innovation with the Micro-PLC and Wireless Connectivity 

• Using IIoT to Navigate the Next Industrial Revolution with Sento and Blues 

The post Navigating Network Sunsets: Future-Proofing Your IIoT Devices with Blues appeared first on Blues.

 This partnership started with the Notecarrier R, a product built to make it easy to integrate Notecard into an Arduino Portenta or MKR board solution.  

 But we didn’t stop there.  

 Today, we launched the Wireless for PLC,  a powerful expansion that brings the Notecard’s plug-and-play wireless connectivity to the Opta PLC ecosystem.  

 Before we get into why we engineered the Wireless for PLC and why it’s set to revolutionize industrial automation…  

 We invite you to learn more about our partnership while exploring Wireless for PLC by joining Blues and Arduino for a fireside chat on Wednesday, June 12, at 1pm ET. Register Now 

 Now, let’s explore Wireless for PLC. 

Solving the IT to OT Disconnect with Wireless Connectivity 

Together, Blues and Arduino set out to solve a critical challenge stifling the progression of industrial intelligence, building automation, and more — The disconnect between operational technology (OT) teams and information technology (IT) teams that all too often blocks brilliant OT applications from reaching production. 

 While these two departments often work harmoniously due to differing priorities and responsibilities, they usually find themselves in juxtaposed positions.  

 IT departments are tasked with managing, maintaining, and, above all, safeguarding enterprises’ technological infrastructure and systems. The success of these departments is measured by system uptime, SLA compliance, response time to threats, the overall number of security incidents, and more.  

 Contrast this with OTs primary responsibilities, and the disconnect is abundantly clear — OT is primarily focused on enhanced industrial efficiency, process optimization, and control system management — all of which often require connectivity and systems that fall under the purview of IT. 

 These competing priorities often stifle OT’s ability to innovate as they need to navigate intensive IT compliance and approval processes. 

 So, what’s the solution? How do we unlock OT innovation while satisfying IT’s requirements?  

 The answer is wireless connectivity over public networks like cellular or LoRa, and with the launch of the Wireless for PLC, that’s precisely what we’ve done.  

From Lotus Notes to Blues: Empowering Teams Through Connectivity 

In the early days of productivity software, products like Lotus Notes, Microsoft Access, and FrontPage sparked a revolution by offering teams and organizations methods of communication without having to rely on their own internal IT department. They had the freedom to set up their own technology and databases internally without waiting for IT to do it. This empowerment allowed marketing, operations, and product teams to take control of their systems and push progress at a rapid pace. 

Lotus Notes, created by Ray Ozzie, Founder & CEO of Blues, empowered teams to collaborate and innovate without the constraints of traditional IT departments. Notes combined email, calendaring, document sharing, and custom application development as an integrated platform, allowing teams to centralize their communication and streamline their business processes. This all-in-one approach eliminated the need for disparate platforms and reduced reliance on IT for essential productivity tools. 

Today, Blues and Arduino are leading a similar revolution, but rather than empowering human-to-human connections, wireless is empowering permissionless machine-to-machine cloud connectivity. 

Local networks like Bluetooth, Ethernet, and Wi-Fi are the domain of IT departments, prioritizing security and reliability above all else. These networks are critical infrastructure, connecting devices and systems within an organization and enabling data flow between them. However, this centralized control often comes at the cost of agility and the progress necessary to remain relevant and competitive. 

 If the revolution in productivity software taught us anything, emboldening teams to innovate on their own terms can lead to breakthroughs that transform entire industries. As wireless connectivity ushers in a new era of machine-to-cloud communication, OT can regain ownership of their technology and push their IIoT projects forward.   

Cellular Connectivity: The Key to OT Autonomy and Agility 

By leveraging wireless technologies like cellular, OT teams can deploy cloud-connected PLCs like the Arduino Opta without relying heavily on IT-controlled local networks like ethernet or Wi-Fi for their connectivity.  

Armed with secure wireless connectivity, OT teams can rapidly bring PLCs and sensors online to demonstrate the value of their IIoT use cases without requiring IT involvement. This newfound autonomy gives them the ability to quickly implement Proofs-of-Concept (PoCs) and pilots, allowing them to iterate, refine, and optimize their IIoT solutions before scaling them enterprise-wide. 

Moreover, wireless connectivity extends the reach of IIoT to hard-to-wire environments, such as remote sites, moving equipment, and temporary installations. OT teams can deploy wireless solutions independently in these scenarios, enabling them to collect more valuable data and further optimize operations in previously inaccessible areas. 

However, enabling IIoT connectivity over networks like cellular is hardly trivial; in fact, such technologies are known for being incredibly complex and requiring years of R&D — that is, until the Wireless for PLC. 

Introducing the Wireless for PLC  

To restore autonomy to industrial OT and product teams, Blues and Arduino, a household name in the maker and professional community, joined forces to create the Wireless for PLC. This powerful expansion brings Notecard’s turnkey, pre-provisioned, and encrypted connectivity to the Arduino Opta micro-PLC. 

 The Arduino Opta micro-PLC brought the easy-to-use, intuitive programming experience Arduino is known for to the PLC market.  

Now, with the Wireless for PLC, we’re taking it a few steps further by offering Opta developers a seamless, compatible route to integrate Notecard’s plug-and-play wireless capabilities with the Arduino Opta micro-PLC.  

 The Wireless for PLC is offered in the Cell+WiFi configuration. With pre-provisioned connectivity and a simple, low-code JSON interface, the Wireless for PLC reduces development time from years to months while bypassing the need to rely on local networks and gain IT’s approval.  

The result? 

OT teams can now focus on developing powerful applications and driving operational efficiency rather than grappling with complex network configurations, security protocols, and bureaucracy. 

In addition to turnkey connectivity, the Wireless for PLC prioritizes security, featuring industry-leading encryption and authentication through an integrated secure element ensuring data security between PLC and cloud while giving both OT and IT teams peace of mind. 

Furthermore, the module’s onboard backup power supply enables power outage detection alerts, giving OT teams an out-of-the-box way to detect and address downtime rapidly.  

 With the launch of the Wireless for PLC, we’ve brought the world of PLCs into a new hassle-free era of cloud connectivity. 

Take the Next Step Toward Cloud-Connected Industrial Automation 

Now, with the easy and flexible Opta PLC Combined with Wireless for PLC’s streamlined device-to-cloud wireless connectivity, OT teams have a direct path to intelligent PLC systems. 

 If you’d like to be among the first to build with the Wireless for PLC, join our waitlist today. 

 Want to learn more about Blues and Arduino’s partnership while discovering what’s possible with the Wireless for PLC? Join us for a fireside chat. 

The post Blues: Fueling IIoT Innovation with the Micro-PLC and Wireless Connectivity appeared first on Blues.