Industrial automation has outpaced the tools used to maintain it. Across parcel hubs, airport baggage systems, and high‑volume manufacturing, equipment now runs faster, harder, and closer to its mechanical limits. Traditional monitoring tools see symptoms, not causes — and almost never at the speed required to prevent failures.
TinMan Systems closes that gap with real‑time, inside‑the‑equipment sensing that reveals vibration signatures, thermal behavior, acoustic patterns, alignment drift, and component wear from the machine’s point of view. Reliability teams gain a unified, multi‑sensor truth about their automation, powered by a platform engineered for continuous operation.
The cost of falling behind is steep. Unplanned downtime now averages $260,000 per hour, with major operations reporting losses up to $1.7M per hour. Across the sector, downtime drains an estimated $852M every week — capital that never returns. In environments where throughput is the business model, even a single failure can cascade into missed service levels, SLA penalties, staffing overruns, and long‑term competitive erosion.
Automation Environments We Diagnose
TinMan Systems delivers engineered visibility from inside the moving equipment that drives modern logistics. Across parcel hubs, ecommerce fulfillment, and airport baggage systems, our platform exposes the vibration, thermal, acoustic, and alignment behavior that determines throughput, reliability, and mechanical health. Explore the full range of environments on our Solutions Overview →.
Advanced Diagnostics for Conveyor Systems
Conveyors are the backbone of high‑volume automation — and often the first place mechanical drift begins. TinMan Systems captures vibration signatures, thermal gradients, acoustic anomalies, and alignment changes from inside the line, revealing early‑stage degradation long before it affects throughput or system stability.
Learn More →High‑Fidelity Diagnostics for Sortation Systems
Sorters operate at extreme duty cycles where friction, brush wear, wheel imbalance, and alignment drift accumulate rapidly. TinMan Systems’ carrier‑integrated sensors capture synchronized vibration, thermal, and video data at full operating speed — exposing degradation patterns that static, externally mounted sensors simply cannot detect.
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Real‑Time Diagnostics for Baggage Handling Systems
Airport baggage systems demand continuous uptime under heavy load. TinMan Systems synchronizes thermal, vibration, acoustic, and positional data across conveyors, EDS lines, and make‑up carousels — giving operators the real‑time insight needed to prevent jams, reduce wear, and maintain consistent passenger flow.
Learn More →TinMan Systems Diagnostic Systems: Deployed Forms of the Sensing Layer
Every diagnostic system from TinMan Systems begins with a core principle: the only reliable way to understand automation is to sense it from within. Our real‑time AI platform synchronizes sensors, video, and motion at operational speed — not as an accessory, but as the foundation for interpreting mechanical behavior. These diagnostic systems extend that philosophy into the field. Whether mounted directly to equipment to feel what it feels, or riding the line like a package to capture the journey through the system, each product delivers a precise, first‑person view of mechanical health that operators can trust and act on.
MCIS [Mobile Conveyor Inspection System]
MCIS is a self‑contained, multi‑sensor inspection unit that rides the conveyor like a package, capturing synchronized vibration, thermal, acoustic, and positional data under true operating load. It exposes drift, friction, imbalance, and early‑stage wear that fixed sensors never see — giving reliability teams the mechanical truth they need to validate assets, commission confidently, and intervene before failures surface.
Explore MCIS →
SORTERVision™
SORTERVision™ embeds TinMan’s sensor suite directly into sorter carriers, capturing vibration, thermal, and video data at full operating speed. It reveals friction spikes, brush wear, wheel imbalance, and alignment drift across every loop — giving operators a complete, inside‑the‑machine understanding of sorter health and cycle stability.
Explore SORTERVision™ →
Cascades System
Cascades provides continuous, wireless multi‑sensor monitoring across conveyors and sorters. It unifies vibration, thermal, acoustic, and video feeds into a single diagnostic stream — delivering real‑time alerts, trend analysis, and early detection of mechanical degradation. Cascades keeps high‑volume operations stable, predictable, and running at peak reliability.
Explore Cascades →The TinMan Systems Platform
The TinMan Systems Platform is the real‑time engine behind every diagnostic system we build — a synchronized, multi‑sensor architecture designed to capture automation from the inside out. It unifies sensing, interpretation, and reporting into one coherent environment, giving operators a complete, first‑person understanding of mechanical behavior at operational speed.
Multi‑Sensor Fusion
Vibration, thermal, video, audio, distance, and orientation — all captured in perfect sync to form a single, time‑aligned mechanical record of every run. This is the foundation that makes TinMan’s inside‑the‑equipment perspective possible.
Real‑Time Interpretation
AI‑driven detection of drift, wear, hotspots, friction spikes, imbalance, and failure precursors — computed live as the system moves. Operators see what the equipment feels, not after the fact, but as it happens.
Synchronized Reporting
Engineering‑grade session replay, raw sensor timelines, and diagnostic overlays that accelerate troubleshooting and root‑cause analysis. Every data stream is aligned to the same clock, giving teams a single source of mechanical truth.
Give your automation a real‑time understanding of itself.
Talk to an engineer, see a live demo, or explore how TinMan Systems integrates with your environment.