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ManufacturingAI & Automation Solutions2022
IoTPredictive MaintenanceML

Predictive Maintenance Platform for Industrial Equipment

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

Our Approach

How we delivered it

1

Instrumented 14 production lines with 280 vibration, temperature, and current sensors, transmitting data via MQTT to a central broker.

2

Built a time-series anomaly detection model using LSTM networks trained on 2 years of historical sensor data and maintenance logs.

3

Developed a maintenance scheduling engine that generates work orders 72 hours before predicted failures, integrated with the client's SAP ERP.

4

Created a plant operations dashboard in Grafana showing real-time equipment health scores, predicted failure probabilities, and maintenance backlog.

5

Conducted a 6-week shadow mode validation where predictions were logged but not acted upon, confirming 91% prediction accuracy before go-live.

Solution Summary

What we built

Deployed IoT sensors and an ML-based predictive maintenance system that forecasts failures 72 hours in advance.

Technology Stack
PythonMQTTApache KafkaInfluxDBTensorFlowGrafanaAWS IoT Greengrass
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