Case Studies

Integrating equipment data across six factories prevented 31 unplanned shutdowns per year

Equipment data previously isolated within individual factories was consolidated on a shared platform. Changes in vibration and temperature trends enabled predictive maintenance and fewer unplanned shutdowns.

Challenges

• Different equipment vendors and data formats at each factory prevented cross-site comparisons.
• Maintenance was mainly reactive, and unexpected shutdowns repeatedly disrupted production plans.
• The project could not add new terminals or extra tasks for production staff.

Our Approach

• Gateways converted signals from existing sensors, collecting data without adding shop-floor work.
• Data formats were normalized into a shared schema, allowing all six factories to be compared using the same metrics.
• Trend-change detection rules were configured by equipment category and incorporated into maintenance planning.
• Notifications were delivered through the existing maintenance system, without introducing another interface.

Results

"Because we could start without adding work on the factory floor, there was very little resistance." - Production Engineering Department

Figures are measured results from the client's environment and do not guarantee equivalent outcomes elsewhere. Information reflects the project at completion.