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Cost of Manual Work — Industrial IoT Platforms
See what repetitive manual work is costing Industrial IoT Platforms teams each year — where legacy PLC and SCADA integration is the platform's largest hidden cost — every plant has a different mix of Rockwell, Siemens, Mitsubishi, Honeywell, and Yokogawa equipment with different protocols (Modbus, Profinet, Ethernet/IP, OPC UA), and the connector work is never done.
What this means for Industrial IoT Platforms
- Legacy PLC and SCADA integration is the platform's largest hidden cost — every plant has a different mix of Rockwell, Siemens, Mitsubishi, Honeywell, and Yokogawa equipment with different protocols (Modbus, Profinet, Ethernet/IP, OPC UA), and the connector work is never done.
- The OT/IT divide is real and political — plant operations teams own the equipment and don't trust IT-led cloud platforms, IT teams own the cloud and don't trust unsigned firmware on the floor, and the platform sits in the middle with neither team as a willing sponsor.
- Industrial IoT has a credibility problem from the GE Predix era — every CIO who lived through a $50M Predix or Siemens MindSphere program that never produced operating value is suspicious of the next platform's promises, and the burden of proof is high.
Where it pays to act
- Edge ML for predictive maintenance — gradient-boosted, time-series, and lightweight neural models that run on edge gateways and flag failures 48-72 hours in advance without requiring constant cloud connectivity.
- Computer vision for in-line quality inspection — defect detection, dimension verification, and assembly verification models that absorb the highest-defect SKUs and reduce final-inspection scrap.
Adjust the inputs to match your Industrial IoT Platforms team.
What manual work costs you
Annual cost
₹6.6 L
People-weeks / year
33
Recoverable via automation
₹4.62 L
Payback
7.8 mo
What this means
Industrial IoT Platforms teams lose 33 people-weeks a year to this work — about ₹6.6 L. Automating the routine ~70% recovers ₹4.62 L a year.
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Cost of manual work — summary
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