Industrial Manufacturer Cuts Unplanned Downtime by 55% with IoT Platform
About the Client
Industrial Equipment Manufacturer
Germany
800 employees
The Challenge
Unplanned equipment downtime was costing $200K per incident in lost production.
Maintenance schedules were calendar-based rather than condition-based, leading to premature or overdue servicing.
No visibility into machine health or production efficiency across the factory floor.
Our Approach
Deployed vibration, temperature, and power consumption sensors across 60 critical machines.
Built ML models using 12 months of historical maintenance data to predict failure probability.
Designed a maintenance technician mobile app with work order management.
The Solution
Launched IoT monitoring platform with real-time machine health dashboards and anomaly alerts.
Deployed predictive models that flag machines 72 hours before expected failure.
Built automated work order creation routing alerts to the correct technician.
Results & Impact
"We went from reactive firefighting to strategic maintenance in 6 months. The ROI in the first year alone was remarkable."
Klaus Weber
Plant Director, Industrial Equipment Manufacturer
