What’s predictive maintenance in manufacturing?
AI & analytics driven solution for equipment maintenance
Predictive maintenance sets forth a conditional based equipment monitoring. Through real-time data collection, IoT, data analysis, and AI, it predicts when a machinery is overloaded, about to break down, or needs rest.
Traditional vs AI-based predictive maintenance
Stop losing your production to unexpected downtimes
| Snowballing costs and fixing works with reactive maintenance | Extended asset lifespan with no disruptions with proactive maintenance |
|---|---|
❌ Fixes equipment after it breaks down. | ✅ Predicts & prevents downtime & failures. |
❌ Machine health wears down due to repeated emergency repairs. | ✅ Asset health & efficiency improves due to on-time fixing. |
❌ Sudden failures put labor safety at risk. | ✅ No unexpected breakdowns; safe work environment guaranteed. |
❌ Sudden failures put labor safety at risk. | ✅ Great for critical equipment with dynamic workloads. |
❌ Manual workflows, fixed schedules even when machine doesn’t require to be tended. | ✅ Condition-based schedules, automated monitoring, and timely alerts raised only when machine needs care. |
Snowballing costs and fixing works with reactive maintenance
❌ Fixes equipment after it breaks down.
❌ Machine health wears down due to repeated emergency repairs.
❌ Sudden failures put labor safety at risk.
❌ Sudden failures put labor safety at risk.
❌ Manual workflows, fixed schedules even when machine doesn’t require to be tended.
Extended asset lifespan with no disruptions with proactive maintenance
✅ Predicts & prevents downtime & failures.
✅ Asset health & efficiency improves due to on-time fixing.
✅ No unexpected breakdowns; safe work environment guaranteed.
✅ Great for critical equipment with dynamic workloads.
✅ Condition-based schedules, automated monitoring, and timely alerts raised only when machine needs care.
Difference between traditional and modern maintenance techniques
Predictive vs. Preventive maintenance
Both are maintenance techniques. But preventive maintenance uses a routine plan to check for failures and make necessary repairs. Example: Religiously shutting down machines and oiling spare parts during month’s beginning.
Preventive maintenance follows a more proactive approach, not waiting for the machinery to give performance deterioration signs. Preventive maintenance might require no setup costs; but it brings forth unnecessary maintenance procedures and downtime.
A maintenance that’s not planned
Benefits of predictive maintenance
Zero unplanned downtime
Low maintenance costs
High equipment life & efficiency
Predictive maintenance in action
From sensors to AI, how PdM works?
IoT devices and sensors collect real-time performance data from machines, including vibration, temperature, emissions, and acoustics.
AI-driven predictive systems are employed to look for anomalies in the collected data, considering both historical data and present data. Upon detecting a potential threat or failure, it alerts the maintenance team, so they can take necessary actions.
How AI helps you predict machinery failures
AI – The core of predictive maintenance
Identifies anomalies
AI is the driving force of predictive maintenance. It helps you identify anomalous behaviors and pinpoint the reasons why it happens.
Sends predictive alerts
Reads into machine logs and real-time data and past failures, identifies potential problems, and raises signals.
Reads complex situations
With deep learning & AI, predictive systems read all types of sensor data including ultrasound images and sounds.
Detects visual defects
Identify on-surface defects like cracks and collisions with the help of computer vision and AI.
Replicate & simulate
Create a digital replica of your unit and perform what-if analysis and simulations to reduce chances of failures.
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Success stories from businesses like you
CPG manufacturers use predictive maintenance analysis to reduce downtime
30%
Reduction in downtime
25%
Maintenance cost reduction
How did packaged goods manufacturers reduce maintenance costs by 25% and improve overall equipment effectiveness with a predictive maintenance approach?
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Improving manufacturing productivity through conveyor operations analysis
12%
Increase in manufacturing efficiency
18%
Reduced reduction rates
Manufacturing company reduces product rejection by 18% addressing operational inefficiencies through data-driven solutions.
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Where can you apply predictive maintenance techniques
Predictive maintenance examples and use cases
Logistics fleet monitoring
Oftentimes, truck oil changes happen even when it’s not needed. Predictive maintenance for logistics assesses machine health and schedules maintenance only when needed.
Factory equipment
Reactive or planned machine downtime and servicing leads to cost wastage and production interruption. AI-based predictive analytics
Aircraft maintenance
Aircraft spares failures can be hazardous and that happens even with routine inspections. With AI predictive maintenance, fuel efficiency, wear and tear, and engine condition could be predicted ahead.