Predictive maintenance
Stop breakdowns 24-48 hours before they happen.
- Who it helps
- Maintenance teams and plant managers dealing with unplanned breakdowns
- Pilot investment
- $22K
- Success metric
- 30%+ reduction in unplanned downtime
The problem
Maintenance teams and plant managers dealing with unplanned breakdowns spend time on work a system could do. This is what it costs today.
- Surprise equipment breakdowns costing 2-4 hours of downtime
- Emergency repairs at premium cost (nights, weekends, rush parts)
- Lost production value during unplanned stops
- Reactive maintenance teams always fighting fires
Time per task (illustrative)
Before: 4.2 hrs/wkAfter: 0.6 hrs/wk
What the automation does
This AI-powered automation module connects to your existing systems, does the repetitive work, and leaves decisions with your team.
- Monitors PLC sensor data: vibration, temperature, current, pressure
- ML model detects anomaly patterns 24-48 hours before failure
- Auto-creates work order in your CMMS system
- Alerts maintenance team via SMS before failure occurs
Prerequisites and limits
These systems and data need to be in place. If they are not, the assessment shows what infrastructure comes first, before you commit to a pilot.
- PLCs connected to network (most facilities already have this)
- Historian logging sensor data (OSIsoft PI, FactoryTalk, Ignition, etc.)
- CMMS tracking failure history (Maximo, Fiix, MP2, etc.)
- 6+ months of historical sensor data for model training
How success is measured
We agree the baseline and the success metric in writing before the pilot starts, then measure from your system data with weekly reports. If the agreed metric is not hit at 90 days, you get a full refund.
Illustrative ROI (NuruState estimate, not a guaranteed result)
- 30-40% reduction in unplanned downtime incidents
- At $2,500/hr downtime cost, 20 incidents/year
- Planned maintenance is 5-8x cheaper than emergency repairs
- Reduced equipment damage from running to failure
Other modules
Find out if predictive maintenance fits your plant
Start with a free 30-minute call. If it fits, the $7,500 assessment scores this module against seven other opportunities with ROI estimates for your facility.