Unplanned equipment downtime was costing a cement manufacturer $180K per incident across 14 production lines.
Team
7 IoT engineers + 3 ML engineers
Timeline
20 weeks end-to-end
Client
Cement Manufacturer (14 production lines)
Outcomes Delivered
67%
Unplanned Downtime Reduction
$820K
Annual Maintenance Savings
72 hrs
Average Failure Prediction Lead Time
Instrumented 14 production lines with 280 vibration, temperature, and current sensors, transmitting data via MQTT to a central broker.
Built a time-series anomaly detection model using LSTM networks trained on 2 years of historical sensor data and maintenance logs.
Developed a maintenance scheduling engine that generates work orders 72 hours before predicted failures, integrated with the client's SAP ERP.
Created a plant operations dashboard in Grafana showing real-time equipment health scores, predicted failure probabilities, and maintenance backlog.
Conducted a 6-week shadow mode validation where predictions were logged but not acted upon, confirming 91% prediction accuracy before go-live.
Deployed IoT sensors and an ML-based predictive maintenance system that forecasts failures 72 hours in advance.
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