AI for Predictive Maintenance in Industrial IoT

AI for Predictive Maintenance in Industrial IoT

Technosurge & AeroDynamic Manufacturing 

Industry: Manufacturing & Industrial IoT

The Challenge:
AeroDynamic Manufacturing, a leader in aerospace components, faced frequent, unexpected downtime on their computer-numerical control (CNC) machines. These breakdowns were costing them over $500,000 annually in lost production, emergency repairs, and delayed orders. Traditional scheduled maintenance was inefficient, often replacing parts that were still functional or missing signs of impending failure. They needed to predict failures before they occurred to transition to a condition-based maintenance model.

The Technosurge AI Solution:
Technosurge implemented an AI-powered Predictive Maintenance platform. We deployed IoT sensors to monitor key parameters on their CNC machines—vibration, temperature, noise, and power draw. Our solution used a stacked machine learning model:

1. Anomaly Detection: An unsupervised learning model established a baseline of “healthy” operation for each machine, flagging any subtle deviations.

2. Predictive Failure Forecasting: A time-series forecasting model (using LSTM networks) analyzed the historical sensor data to predict the Remaining Useful Life (RUL) of critical components like spindles and ball screws.

The system provided dashboard alerts to maintenance teams, predicting failures with a 30-day horizon and a 95% confidence rate.

The Outcome:

• 70% Reduction in Unplanned Downtime: Maintenance was scheduled during planned pauses in production.

• 20% Reduction in Maintenance Costs: Parts were replaced only when necessary, not on a fixed schedule.

• Increased Overall Equipment Effectiveness (OEE): Production lines became more reliable and efficient.

• ROI: The client achieved a full return on investment within 8 months of implementation.

Why This Case Study is Strong for Technosurge:

• Cross-Industry Appeal: The concept applies to manufacturing, energy, logistics, and any sector with physical assets.

• Tangible ROI: It demonstrates clear, quantifiable financial benefits, which is a top priority for potential clients.

• Showcases Technical Depth: It goes beyond simple classification and involves sophisticated time-series forecasting and IoT integration.