Pilot plant
One plant. Streaming ingest, baseline anomaly detection, shop-floor dashboard.
Multi-plant manufacturer. Predictive-maintenance platform built to reduce unplanned downtime.
Predictive-maintenance platform built to reduce unplanned downtime.
i
This is a representative engagement pattern, not a specific named client. The metrics listed are what this kind of work is measured on, not results. We share named references on a private intro call, with the client’s explicit permission.
Engagement · 8 monthsIndustrialAI in production
Illustrative
Downtime
Unplanned downtime
Savings
Maintenance savings
Rollout
Plants live
Challenge
A multi-plant manufacturer was bleeding money to unplanned downtime. Sensor data was already being collected, nobody was acting on it.
Approach
- Streaming data lake aggregating signals across every plant, with a pragmatic schema.
- Anomaly-detection models tuned per asset class, with a refreshingly boring operator UI.
- Roll-out plant-by-plant, with operator champions and a 'do not surprise the floor' rule.
Outcome
Designed to reduce unplanned downtime and maintenance cost, rolled out plant by plant so the shop floor is never surprised.
Brief us on your engagementHow we ran it
The shape of the engagement.
Model tuning
Per-asset-class anomaly detection, calibrated to the floor, validated by operators.
Operator UI
Boring on purpose: high contrast, large hit targets, clear escalation, zero surprises.
Full rollout
Plant-by-plant rollout with on-site training, operator champions, and zero shop-floor disruption.
Services involved
Capabilities we deployed.
Stack we shipped with
The tools that did the work.
AWS IoT
Apache Kafka
Snowflake
TimescaleDB
scikit-learn
PyTorch
Grafana
Datadog
What we measure
Multi-plant manufacturer · the scorecard.
Metrics agreed in week one, reviewed weekly with the sponsor and reported quarterly to the exec team.
- Business metrics, not vanity metrics.
- Multiple capabilities, one accountable team.
- Stack chosen for fit, not familiarity.
Downtime
Unplanned downtime
Savings
Annualised maintenance savings
Rollout
Plants live
Safety
Shop-floor incidents during rollout
"A streaming data lake, anomaly-detection models, and a refreshingly boring operator UI, installed plant by plant to avoid disruption."
More work
Other engagements worth a look.
Let's build
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