Lowering IoT TCO through smart manufacturing

When companies plan to deploy IoT devices, whether for industry, smart buildings, or logistics, they often focus on hardware pricing. That’s understandable; it’s the first number that stands out. But the purchase cost is just a small fraction of the Total Cost of Ownership (TCO). The real expenses lie in deployment, configuration, integration, management, and maintenance.

Think of buying a car. You’re not just paying for the vehicle. You also have to consider insurance, servicing, fuel, and potential repairs. The same goes for IoT. Costs tied to technical staff, software development or troubleshooting can quickly outweigh the device’s purchase price. The good news is that modern IoT manufacturers, such as ACRIOS, are designing solutions that reduce TCO from the ground up. Here’s how.

Preconfigured devices directly from the manufacturer

One of the most effective ways to reduce TCO is through ready-to-use devices delivered directly from the manufacturer. Instead of spending hours configuring each unit on site, the supplier can tailor the device in advance to meet your specific requirements. Key features of ready-to-use devices include:

• ‍Custom firmware installation: Devices come with software tailored to the project, e.g. a temperature sensor pre-set to send data at required intervals.
• ‍Parameter configuration: Communication protocols or data transmission frequency can be preloaded.
• ‍Active SIM cards: The device connects immediately to the network, no manual activation needed.
• ‍Pre-shipment testing: Every unit is verified before delivery to prevent installation issue.

Imagine receiving a sensor that works straight out of the box. No field configuration, no risk of human error. This saves time, reduces the load on your tech team, and accelerates deployment.

Integration tools that save weeks of effort

Another cost-cutting benefit lies in software tools provided by the manufacturer. Instead of building everything from scratch, you can use ready-made solutions:

• ‍Sensor data processing  tools: These interpret raw sensor inputs and format them for easy integration into ERP systems, dashboards, or other applications.‍
• Containerised backend apps: Preconfigured Docker apps can be deployed in minutes – with no need to set up complex servers.

With these tools, onboarding a device can take days instead of weeks. That means fewer external developers, less time spent coding, and faster time-to-value.

Remote management for lower maintenance costs

Modern IoT devices don’t stop at installation. They include features that reduce ongoing maintenance and increase flexibility:

• ‍Over-the-air updates (FUOTA): Devices can receive firmware updates remotely. No need to send a technician on site.‍
• Remote configuration: Change settings like transmission intervals directly from the web interface.

These features save money on service calls, extend device lifetime, and allow quick adaptation to changing project needs.

Operational efficiency drives long-term savings

Manufacturers also help reduce TCO by building in features that optimise day-to-day operation:

• ‍Minimised data transmission: Devices send only essential data, saving bandwidth and mobile network costs.‍
• Battery life estimation: Algorithms predict battery replacement timelines, allowing for better planning and fewer disruptions.‍
• Precise battery health metrics: Using components like coulomb counters, some devices can report actual energy levels – not just voltage – making battery management much more accurate.

A full-stack solution for low-effort deployment

When combined, these elements form a complete solution covering the full lifecycle of IoT devices:

• ‍Preconfigured hardware  with SIM: Ready to use from the box.‍
• Software tools for integration: Simplify onboarding into your systems.‍
• Backend apps for data  analysis and control: Speed up time to value.‍
• Efficiency features: Lower operating and maintenance costs.

You don’t need to piece everything together – a quality supplier delivers a streamlined solution from start to finish.

Choose a partner who cares about TCO

Focusing only on the price of the hardware may seem cost-effective at first – but true savings come from considering the total cost of ownership. The right IoT supplier provides preconfigured devices, ready-to-use software, and lifecycle support that saves time, money and stress. Whether you need plug-and-play sensors, remote updates, or battery life optimisation, the right partner helps you deploy faster, smarter, and more cost-effectively.

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