IoT Based Predictive Maintenance Solutions
AI Powered Early Fault Detection | Condition Monitoring | RUL Prediction
Current Scenario of Maintenance
1000–5000 rotating equipment in a typical plant
Managed by limited maintenance staff
Manual inspection (touch, hear, visual guess)
Quarterly offline measurement by vendors
Sudden failures still occur frequently
Challenges in Traditional Maintenance
Inaccurate diagnosis (skill dependent)
No real-time asset visibility
Late detection of faults
No historical fault tracking
Reactive rather than proactive maintenance
This Leads To
Unplanned equipment downtime
Reduced machine life
Higher spare parts usage
Production loss & increased OPEX
Inefficient manpower utilization
Value of IoT Based Predictive Maintenance
24×7 vibration, temperature & sound monitoring
AI/ML based health scoring
FFT analytics for deep diagnostics
Remote visibility from anywhere
Monthly expert reports
20–40% reduction in downtime
Data Collection from Machine Body
High-accuracy vibration & temperature sensors collect continuous machine health data for ML & predictive maintenance.
Faults That Can Be Diagnosed
Bearing Faults
Unbalance
Misalignment
Mechanical Looseness
Gear Mesh Faults
Resonance & Soft Foot
Temp Abnormalities
Predictive Maintenance Architecture
Dashboard Visibility
System Alerts
Automatic instant alerts for deviations
SMS / Email / WhatsApp Notifications
Configurable thresholds
Critical + Warning-level notifications
Motor Health KPI
Machine Health Score
Vibration Severity Index
Temperature Trend Index
Failure Probability Score
Realtime Data Monitoring
Live vibration waveform
Real-time FFT spectrum
Continuous temperature logs
RPM, load & performance insights
Remaining Useful Life (RUL)
AI/ML-based life prediction helps schedule maintenance before failure.
Equipment History
Complete audit trail of past faults, vibration patterns, and maintenance logs.
📞 Get in Touch With Us
Our team will help you with system design, BOQ, pricing, integration support and complete deployment planning tailored for your facility.