Worker Efficiency Monitor

A Smart Industrial Production Monitor (IIoT).

1. Project Overview

Sector: Manufacturing.

Device Type: Automated Worker Efficiency Monitor.

Role: Senior IoT Engineer (Firmware & Hardware Architect )

Core Tech: ESP32, FreeRTOS, MQTT, REST API, Android App

The Challenge:

In the labour-intensive garment sector, production targets are dynamic. Supervisors lacked real-time visibility into "Micro-Stoppages," and workers lacked immediate feedback on their performance.

The Solution:

I engineered an edge-computing IIoT device that gamifies the production floor. The device tracks "Target vs. Actual" metrics in real-time, adjusts goals dynamically using a "Carry-Over" algorithm, and provides visual/audio feedback to keep workers in the "Green Zone."

2. Hardware Abstraction Layer (HAL)

The system is built on a robust hardware architecture designed to handle high-frequency user interaction and data logging simultaneously.

MCU: ESP32 (Dual Core) utilized for its multi-threading capabilities.
HMI (Human Machine Interface):
- Visual: 320x240 TFT Touchscreen (ILI9341 Driver) utilizing the TFT_eSPI library for high-speed rendering.
- Input: 8x Physical Push Buttons managed via a PCF8574 I2C Expander. These are used for rapid increment/decrement of production counts (simulating machine sensor inputs) and menu navigation.
Audio Feedback: MAX98357A I2S DAC amplifier delivering voice prompts and alerts.
Storage: SD Card (SPI) for config files, assets, and Excel-compatible CSV logging.

3. Firmware Architecture: FreeRTOS Implementation

To ensure a non-blocking user experience, I architected the firmware using FreeRTOS with distinct parallel tasks:

Task Orchestration:
- ProductionTask: Handles the core business logic, stopwatch, and shift management.
- serverTask: Runs an asynchronous HTTP Web Server (Port 8080) for API communication.
- tftLoopTask: Dedicated GUI rendering task. I implemented Mutex Semaphores (tftMutex) to prevent SPI bus collisions between the Display and SD Card.
System Reliability:
- Watchdog Timer: Implemented esp_task_wdt to auto-restart individual tasks if they hang.
- Power-Loss Recovery: The system writes volatile state to PM_Running.json every few seconds, allowing it to resume exactly where it left off after a power outage.

4. Software Ecosystem & Connectivity

The system creates a "Connected Floor" utilizing a Local Network architecture to ensure data security and high-speed transmission.

MQTT Telemetry:
The device functions as an MQTT Client, publishing critical production metrics (Real-Time Count, Efficiency %, Active Time) to a Local Server/Broker for centralized logging.
REST API:
Endpoints (e.g., /production_running_json) allow for direct querying of device telemetry.
Mobile Application (Management Tool):
I developed a companion Android Application tailored for Industrial Production Engineers (IPEs).
- Live Dashboard: View real-time status of all connected devices on the floor.
- Data Export: Download daily production logs via CSV directly from specific devices or the server.
- Wireless Configuration: Remotely set the "Standard Minute Value" (SMV) and hourly targets for specific lines without physical access.

5. Operational Workflow

The device integrates seamlessly into the daily factory routine:

Setup:
The Line Chief sets the daily target and SMV via the TFT Touch screen or wirelessly using the Mobile App.
Operation:
As the worker finishes a garment, the count increases (triggered via the Physical Button or an external sensor).
Calculation:
The ESP32 calculates Real-Time Efficiency (%) based on elapsed time vs. the adaptive target.
Feedback (Gamification):
- If On Track: The display shows Green indicators, reinforcing positive performance.
- If Slow: The I2S Audio system plays a specific warning alert, and the display flags the delay (Red/Orange status).
Reporting:
All data is synced to the server via MQTT, allowing the management team to analyze bottlenecks and historical performance.

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Worker Efficiency Monitor

A Smart Industrial Production Monitor (IIoT).

1. Project Overview

Get in touch at "ramim.cse.uctc@gmail.com"

https://www.facebook.com/IoTWithRamim/
linkedin.com/in/ramim256
+8801836655062

Worker Efficiency Monitor

A Smart Industrial Production Monitor (IIoT).

1. Project Overview

Get in touch at "ramim.cse.uctc@gmail.com"

https://www.facebook.com/IoTWithRamim/linkedin.com/in/ramim256+8801836655062

https://www.facebook.com/IoTWithRamim/
linkedin.com/in/ramim256
+8801836655062