FAQ & Troubleshooting

Frequently Asked Questions

General Questions

What is IoTFlows?

IoTFlows is a comprehensive manufacturing intelligence platform that combines plug-and-play IIoT hardware (SenseAi, SenseAi Embedded, BeamTracker) with cloud-based software to monitor machine utilization, track production, analyze downtime, and improve overall equipment effectiveness (OEE).

Do I need to integrate with my PLC or machine controls?

No! IoTFlows devices are completely non-intrusive. They attach magnetically or mount externally with no wiring, PLC integration, or modification to your existing equipment. This makes installation quick, safe, and reversible.

How long does installation take?

Most installations are complete in minutes:

• SenseAi: 5-10 minutes per machine (mount sensor, power on, connect to WiFi)
• BeamTracker: 10-20 minutes (mount, align laser, connect to WiFi, basic calibration)
• SenseAi Embedded: Varies by integration complexity (typically 30-60 minutes)

Do I need IT support or special network configuration?

Not if you use the IoTFlows 4G/LTE router (recommended). The router creates an isolated cellular network that requires zero IT coordination. If you prefer to use your facility WiFi, devices need basic 2.4 GHz WiFi access and outbound HTTPS (port 443) — no special firewall rules or inbound ports required.

What kind of machines can I monitor?

IoTFlows works with virtually any industrial equipment:

• CNC machines (mills, lathes, grinders, EDMs)
• Stamping presses and press brakes
• Injection molding machines
• Packaging equipment
• Assembly lines
• Laser cutters and waterjet systems
• Robotic cells
• Any equipment that vibrates, moves, or produces countable output

Product-Specific Questions

What's the difference between SenseAi and SenseAi Embedded?

• SenseAi: External vibration/acoustic sensor that mounts magnetically on machines. Best for retrofitting existing equipment. Plug-and-play, no integration needed.
• SenseAi Embedded: IP67 version for OEM installation or deeper integration with more advanced health condition monitoring and predictive maintenance.

How does BeamTracker count parts?

BeamTracker uses a precision laser/LiDAR sensor to detect objects passing through the beam. Each interruption is counted as one part. Works with any visible object on conveyors, assembly lines, or production flows.

Can I use multiple devices on one machine?

Yes! Many customers use:

• SenseAi for utilization tracking + BeamTracker for part counting
• Multiple SenseAis on complex multi-spindle machines
• SenseAi + external sensors via SenseAi Embedded

Platform & Software Questions

Can I access IoTFlows from my phone?

Yes! The platform is fully mobile-responsive via web browser, and we offer dedicated iOS and Android apps:

• iOS App
• Android App

How do I add more users to my organization?

1. Click the Users icon in the top-right corner
2. Go to the Members tab
3. Click Add Member
4. Enter their email and assign a role (Owner, Administrator, Member, Observer)
5. They'll receive an invitation email to create their account

Can I customize downtime reason codes?

Yes! Navigate to Organization Settings → Auto Downtime Classification to:

• Create custom downtime categories
• Define automatic classification rules
• Set severity levels (Low, Medium, High)
• Organize codes by department or machine type

How do I export data?

Most pages include a CSV export button:

• Downtimes report → Export downtime events
• Advanced Report → Export utilization data
• Shift Production → Export production data
• Historical Production → Export trends

Use exported data for custom Excel analysis, ERP integration, or executive reporting.

Can I display dashboards on TV screens?

Yes! Use the TV icon in the top-right corner to share your current view to IoTFlows-provided Chromecast devices. Perfect for shop floor displays, management offices, and department performance boards.

Common Issues & Troubleshooting

Device Connectivity Issues

Device showing offline in the platform

Symptoms: Device appears red/gray in Devices Tab, no recent data

Steps to resolve:

1. Check power: Verify the device is powered on (LED should be lit)
2. Check WiFi: Ensure the WiFi network is operational
3. Check range: Move IoTFlows router closer (within 100 ft / 30 m)
4. Restart device: Unplug power, wait 10 seconds, reconnect
5. Re-provision WiFi: Use mobile app to reconnect to WiFi (if network changed)
6. Contact support: If issue persists after these steps

Weak WiFi signal

Symptoms: Intermittent connectivity, delayed data updates

Solutions:

• Relocate IoTFlows router to a more central location
• Move router away from metal enclosures or machinery
• Place router near a window for better cellular signal (if using 4G/LTE)
• Add WiFi extenders or access points if needed
• Reduce distance between devices and router

Can't connect device to WiFi

Symptoms: Mobile app can't find device, pairing fails

Steps to resolve:

1. Verify Bluetooth is enabled on your phone
2. Ensure device is in pairing mode:
   • SenseAi: Hold left button for 10 sec until LED blinks blue
   • BeamTracker: Navigate to WiFi setup screen on device
3. Stand close to device during pairing (within 10 feet)
4. Use 2.4 GHz WiFi only (devices don't support 5 GHz)
5. Try a different phone if pairing repeatedly fails
6. Contact support for advanced troubleshooting

Production Tracking Issues

Production count seems too high

Possible causes:

• Algorithm detecting vibrations/noise as production cycles
• Sensor picking up non-production activity
• Incorrect algorithm selected

Solutions:

1. Navigate to Production → Parts List
2. Edit the operation
3. Try switching from Continuous Analysis to Discrete Analysis
4. Increase the Downtime Filter percentage to ignore brief stoppages
5. Verify sensor is mounted in optimal location (close to actual production point)

Production count seems too low

Possible causes:

• Sensor not detecting all cycles
• Downtime filter too aggressive
• Wrong algorithm selected

Solutions:

1. Check sensor placement and ensure it's detecting vibration/motion
2. Switch from Discrete Analysis to Continuous Analysis
3. Reduce Downtime Filter percentage
4. Verify machine is actually running at expected rate
5. Recalibrate device (see product calibration guides)

Cycle time doesn't match expectations

Possible causes:

• Incorrect algorithm configuration
• Machine running slower/faster than design specs
• Operator technique variations

Solutions:

1. Run production for 1-2 full shifts to collect data
2. Calculate average cycle time from actual production: Total shift time / Parts produced
3. Update the cycle time in Parts List to match observed reality
4. Investigate if machine is underperforming (maintenance needed)

Downtime Tracking Issues

Not seeing downtime events I expect

Possible causes:

• Events too short (filtered by downtime filter)
• Auto-classification rules hiding events
• Events not within selected shift/date range

Solutions:

1. Check Parts List downtime filter settings
2. Review Auto Downtime Classification rules
3. Expand date range and shift filter in Downtimes page
4. Look for short events that might be automatically classified

Too many small downtime events cluttering the report

Solutions:

1. Increase the Downtime Filter in Parts List
2. Create Auto Downtime Classification rules to automatically categorize common short events (breaks, micro-stops, shift changes)
3. Use filtering in the Downtimes page to hide low-severity events

OEE & Utilization Issues

OEE/Utilization seems too low

Possible causes:

• Unrealistic OEE goal set too high
• Shift schedule longer than actual production hours
• Unplanned downtime driving down metrics

What to do:

1. Review Downtimes page to identify biggest losses
2. Check if Shift Management settings match actual production hours
3. Adjust OEE goals to realistic levels (60-80% is typical for most operations)
4. Address root causes of downtime (see Pareto chart in Downtimes page)

OEE goal not showing correctly

Solutions:

1. Verify organization-wide goal: Click utilization % in Assets Tab → Overview
2. Check machine-specific goals: Click utilization % for individual machines
3. Ensure goals are set as percentages (e.g., "70%" not "0.70")

Calibration Issues

BeamTracker not counting accurately

Symptoms: Counts are off, missing parts, double-counting

Solutions:

1. Recalibrate max distance:
   • Go to BeamTracker device settings (on-device menu)
   • Place a part in front of the laser
   • Set max distance to slightly beyond the part
2. Adjust web dashboard settings:
   • Navigate to device settings in platform
   • Configure trigger sensitivity and min/max thresholds
3. Verify mounting:
   • Laser should be perpendicular to part flow
   • No obstructions in beam path
   • Stable mounting (no vibration affecting alignment)

SenseAi not detecting machine states correctly

Solutions:

1. Reposition sensor:
   • Move closer to spindle or vibration source
   • Avoid mounting on panels that dampen vibration
   • Use metal-to-metal contact for best sensitivity
2. Recalibrate thresholds:
   • Run machine for several cycles
   • Platform learns normal patterns
   • May take 1-2 shifts to stabilize
3. Review Parts List algorithm settings

Billing & Account Issues

How do I update my billing information?

1. Click your profile picture (top-right)
2. Select Billing
3. Update payment method, billing address, or subscription details

How do I add more devices or change my plan?

Contact our sales team via the IoTFlows website or email support@iotflows.com to discuss plan upgrades or additional devices.

Can I get a refund if I'm not satisfied?

Please contact our support team to discuss your experience. We're committed to ensuring IoTFlows delivers value to your operation.

Still Need Help?

Contact Support

• Email: support@iotflows.com
• Response time: Typically within 24 hours (business days)
• Include in your message:
  • Description of the issue
  • Device type and ID (if applicable)
  • Screenshots (if helpful)
  • When the issue started

Request a Demo or Training Session

If you or your team need help getting started or want to explore advanced features, contact our team to schedule a live demo or training session:

• Website: iotflows.com
• Email: support@iotflows.com

Provide Feedback

Use the feedback icon in the platform to share suggestions, report bugs, or request new features. We actively review all feedback and use it to improve IoTFlows.