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Predicting machine failure before production stops
A mid-sized auto-components manufacturer needed one reliable operational view across two plants and more than 120 CNC machines. We built a live AI Digital Twin that converted fragmented machine signals into early warnings and practical maintenance actions.
Teams were reacting after failure
Machine data lived in isolated PLCs and shift reports. Maintenance teams had no reliable way to identify abnormal vibration, temperature or cycle-time patterns before breakdowns. Manual reporting also made plant-wide comparisons slow and inconsistent.
A real-time operational nervous system
We connected machine telemetry to a unified digital representation of every critical asset. Predictive models learned normal operating ranges, surfaced anomalies and delivered prioritized alerts with the context technicians needed to act.
- Live OEE and asset-health dashboards
- Predictive maintenance scoring
- Temperature and vibration anomaly alerts
- AI maintenance copilot for root-cause guidance
Business impact Maintenance shifted from reactive work orders to planned intervention, increasing production continuity without adding headcount.





