The Problem
A gearbox fails at 03:14 on a Tuesday. Production stops for nine hours. The signals were in the vibration trace for three weeks, in the oil sample for two, in the casing temperature for nine days, but nobody was reading them together.
Bespoke System Live
Predictive Maintenance System
Every bearing, motor and compressor has a voice. The system listens, learns the shape of failure, and books the repair before the breakdown.
- Industry
- Mining, cold-chain, facilities, fleet operators
- Best for
- Operators whose unplanned breakdowns cost more in a single day than the system costs in a year
In short
What is predictive maintenance?
Predictive maintenance pulls vibration, temperature, oil-analysis, and run-hour data into one model per asset class, predicts days-to-failure with a confidence band, and books the intervention at the lowest-cost downtime window. It shifts maintenance from calendar-driven to condition-driven, catching the breakdown before it happens, when the warning signs were already in the data.
How we work
We sit with your business. We find the operational problem costing you the most. We build the system that fixes it.
What We Built
A fleet-wide monitor that pulls vibration, temperature, oil analysis and run-hour data into one model per asset class. The model predicts days-to-failure with a confidence band, auto-schedules the intervention, reserves the part, notifies the technician, and proposes a downtime window that costs the least to take.
What Changed
Unplanned breakdowns dropped because the system saw them coming. Maintenance shifted from calendar-driven to condition-driven, fewer scheduled changeouts on healthy assets, far fewer 3am callouts on sick ones. One prevented breakdown usually pays for the system.
Example deployment
One example of how we'd wire this capability. We'd shape it to your business.
Live demo
Predictive Maintenance, Gearbox fleet
Fleet
40gearboxs
Healthy
25
Watch
11
Critical
4
Fleet dashboard
Sortable health view · click any flagged asset
AssetName · concernHealthDTFCrit.
Healthy assets are not clickable. Tap a Watch or Critical asset to open its detail panel.
Select a flagged asset.
Pick any amber or red asset from the list to see its sensor traces, the auto-scheduled intervention, and the cost of doing nothing.
Want one built for your business? The first conversation is free.
Book a discovery call How it fits the three pillars
One system, three jobs.
Automation
A flagged asset auto-reserves parts, opens a work order, notifies the right technician, and books a downtime window against the production calendar, no human keystroke between the signal and the schedule.
Explore AutomationAudit Trails
Not the primary focus for this system.
Anomaly Detection
Per-asset signatures replace generic thresholds. The model knows what THIS gearbox looks like healthy, and flags drift weeks before a hard alarm would trip.
Explore Anomaly DetectionAnalytics
Days-to-failure, confidence, downtime cost and lost-production cost all rendered against the same fleet, so the operator can sequence interventions by impact, not by who shouted loudest.
Explore Analytics FAQ
Frequently asked questions
- What’s the difference between preventive and predictive maintenance?
- Preventive maintenance services equipment on a fixed schedule, whether it needs it or not. Predictive maintenance reads the asset’s actual condition and intervenes only when failure is approaching, fewer scheduled changeouts on healthy machines, far fewer 3am callouts on sick ones.
- How does it predict a failure?
- A model per asset class watches vibration, temperature, oil analysis, and run-hours together, the signals that show up weeks before a breakdown but that no one reads in combination. It predicts days-to-failure, reserves the part, and proposes the cheapest downtime window to take.
- Is predictive maintenance worth it?
- One prevented breakdown usually pays for the system. A gearbox that fails mid-shift can stop production for hours, and the warning was often in the data for weeks. Catching it converts an unplanned stop into a scheduled, low-cost intervention.
Related systems
Systems we often build alongside this one.
- Forecasting & Demand PlanningEighteen months of your numbers, projected forward. The orders, shifts and cash buffers it implies land where the team already works.
- Analytics & Decision Support SuiteOne platform pulling from every system in the business, shaped four different ways for the four people who run it.
- Continuous Assurance EngineBackground monitoring across a stream of activity no human could realistically watch, only the things that matter surface, with their evidence already attached.
- Decision EngineThree reviewers, three different answers on the same case. Make the call once, then have every reviewer reach it the same way, every time.
Next Step
Want one built for your business?
The first conversation is free. And useful either way.