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Manufacturing
AI Predictive Maintenance Platform Custom AI Solutions
A mid-sized manufacturer kept losing shifts of output to unplanned machine failures.
Manufacturing
Industry
8 tools
Stack
Client
SteelCraft Industries
Industry
Manufacturing
Service
Custom AI Solutions
Stack
TensorFlow, Python, Apache Kafka
01
Challenge
“A mid-sized manufacturer kept losing shifts of output to unplanned machine failures.”
Ten years of work-order history sat unread, and OEM alerts were too noisy or too late to act on.
02
Build
We deployed IoT vibration and current-draw sensors on critical machines, streamed telemetry through Apache Kafka, trained a deep-learning failure-prediction model in AWS SageMaker, and built a planning UI that shows the next 14 days of expected failures - with engineering signing off each AI-flagged work order.
03
Outcome
67% less unplanned downtime within four months and an estimated US$4.2M in avoided downtime and callout costs a year.
Deliverables
What the system does — functionality shipped.
- 67% reduction in unplanned downtime within 4 months. Estimated US$4.2M in avoided downtime + emergency-callout savings annually. 14-day prediction window with 88% precision on critical-asset alerts. Spare parts inventory rebalanced around predicted demand. Maintenance team moved from firefighting to scheduled work.
Technologies
TensorFlowPythonApache KafkaAWS SageMakerAWS IoT CoreReactPostgresGrafana
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Case study © AorBorC Technologies · aorborc.com · +1 (872) 267-2672 (872-AORBORC)