Predictive Maintenance
Trusted by 400+ leading companies
Live Monitoring

AI-Powered Predictive Maintenance
for Industrial Equipment

AI-powered predictive maintenance solution that monitors equipment health in real-time and predicts failures 2-8 weeks in advance. Transform your maintenance strategy from reactive to predictive with 95% accuracy failure prediction.

95%+
Prediction Accuracy
50%
Downtime Reduction
2-8
Weeks Notice
3-8
Months Payback
Predictive Maintenance Dashboard

Complete Predictive Maintenance System

Comprehensive hardware and software solution designed for industrial environments

Vibration Sensors

Wireless tri-axial accelerometers for rotating equipment monitoring

±16g measurement range
10kHz frequency response
Battery life: 5+ years
IP67 waterproof rating
Magnetic mounting system
SPECIFICATIONS
Range: ±16g | Frequency: 10kHz | Battery: 5+ years | Rating: IP67

Temperature Sensors

High-precision thermal monitoring for critical equipment points

±0.1°C accuracy
-40°C to +125°C range
Wireless transmission
Real-time alerts
Multiple probe types
SPECIFICATIONS
Accuracy: ±0.1°C | Range: -40°C to +125°C | Type: Wireless RTD/Thermocouple

Pressure Transducers

Industrial-grade pressure monitoring for hydraulic and pneumatic systems

0-10,000 PSI range
±0.25% accuracy
4-20mA output
Explosion-proof housing
Digital display option
SPECIFICATIONS
Range: 0-10,000 PSI | Accuracy: ±0.25% | Output: 4-20mA | Rating: Ex-proof

Current Sensors

Non-invasive motor current analysis for electrical fault detection

Split-core design
0.1A to 6000A range
±1% accuracy
Easy installation
Phase monitoring
SPECIFICATIONS
Range: 0.1A to 6000A | Accuracy: ±1% | Type: Split-core CT | Phases: 3-phase

Edge Gateway

Industrial IoT gateway with local processing and AI capabilities

ARM Cortex-A72 processor
16GB storage capacity
Multiple connectivity options
Local AI processing
Redundant power supply
SPECIFICATIONS
CPU: ARM Cortex-A72 | Storage: 16GB | Connectivity: 4G/WiFi/Ethernet | Power: Redundant

Analytics Platform

Cloud-based AI platform for predictive analytics and maintenance optimization

Machine learning algorithms
Real-time dashboards
Mobile applications
API integrations
Custom reporting
SPECIFICATIONS
Platform: Cloud-native | ML: TensorFlow/PyTorch | API: RESTful | Mobile: iOS/Android

Advanced Predictive Capabilities

Cutting-edge AI and machine learning technologies that revolutionize maintenance operations

95% Accuracy

Advanced AI Algorithms

Machine learning models trained on millions of equipment data points to predict failures with 95% accuracy

Proprietary failure prediction models
Continuous learning and improvement
Industry-specific algorithm tuning
Real-time anomaly detection
Pattern recognition capabilities
Advanced AI Algorithms
2-8 Weeks Notice

Early Warning System

Multi-level alert system that provides 2-8 weeks advance notice of potential equipment failures

Configurable alert thresholds
Multi-channel notifications
Escalation procedures
Priority-based alerting
Historical alert tracking
Early Warning System
Real-time Monitoring

Performance Analytics

Comprehensive equipment performance monitoring with trend analysis and benchmarking

Real-time performance metrics
Historical trend analysis
Equipment benchmarking
Efficiency optimization
Performance reporting
Performance Analytics
30% Schedule Optimization

Smart Scheduling

AI-driven maintenance scheduling that optimizes timing based on actual equipment condition

Condition-based scheduling
Resource optimization
Maintenance calendar integration
Work order automation
Spare parts planning
Smart Scheduling
Instant Health Assessment

Equipment Health Scoring

Proprietary health scoring system that provides instant equipment condition assessment

0-100 health score scale
Color-coded status indicators
Health trend tracking
Comparative analysis
Risk assessment matrix
Equipment Health Scoring
24/7 Mobile Access

Mobile Command Center

Comprehensive mobile application for maintenance teams with offline capabilities

Real-time notifications
Offline data access
Photo/video documentation
Work order management
Team collaboration tools
Mobile Command Center
Questions? Projects? Let’s Collaborate

Want a demo or quick consult? Message us.

Implementation Process

Structured approach ensuring smooth deployment and maximum value realization

1-2 weeks

Site Assessment & Planning

Comprehensive evaluation of your facility and equipment to design the optimal monitoring strategy

KEY DELIVERABLES:
Equipment inventory and criticality analysis
Sensor placement optimization plan
Network infrastructure assessment
Implementation timeline and milestones
ROI projection and business case
1 week

System Design & Configuration

Custom system design tailored to your specific equipment and operational requirements

KEY DELIVERABLES:
Detailed system architecture design
Sensor configuration specifications
Dashboard and alert customization
Integration requirements document
Testing and validation protocols
2-3 weeks

Hardware Installation

Professional installation of sensors and gateway equipment with minimal operational disruption

KEY DELIVERABLES:
Sensor installation on critical equipment
Gateway deployment and configuration
Network connectivity establishment
Initial system testing and validation
Installation documentation and certificates
1-2 weeks

System Commissioning

Complete system activation with baseline establishment and initial AI model training

KEY DELIVERABLES:
System activation and baseline setup
AI model training initiation
Alert threshold configuration
User account setup and permissions
Initial performance validation
1 week

Training & Go-Live

Comprehensive team training and ongoing support to ensure successful system adoption

KEY DELIVERABLES:
Comprehensive user training program
System documentation and manuals
24/7 support activation
Performance monitoring setup
Continuous improvement planning
Looking for Real-Time Alerts?

We’ll help you set them up right.

Industry Applications

Proven solutions across diverse industries with measurable results

Manufacturing

CHALLENGE
Unplanned downtime costs $50,000 per hour in automotive manufacturing
SOLUTION
Real-time monitoring of production line equipment with predictive failure alerts
RESULTS
45% reduction in unplanned downtime, ₹2.5Cr annual savings
CASE STUDY
Tata Motors reduced maintenance costs by 35% while improving OEE by 12%

Oil & Gas

CHALLENGE
Critical pump failures can cause production losses exceeding ₹1Cr per incident
SOLUTION
Comprehensive monitoring of rotating equipment with vibration and temperature analysis
RESULTS
60% reduction in critical failures, 99.2% equipment uptime achieved
CASE STUDY
ONGC prevented 8 critical failures, saving ₹12Cr in production losses

Power Generation

CHALLENGE
Turbine failures can cost ₹5-10Cr in repairs plus lost generation revenue
SOLUTION
Advanced vibration monitoring with AI-powered turbine health assessment
RESULTS
50% reduction in maintenance costs, 15% improvement in availability
CASE STUDY
NTPC extended turbine life by 25% through predictive maintenance

Mining

CHALLENGE
Heavy equipment downtime costs ₹2-5 lakhs per hour in lost production
SOLUTION
Rugged sensors for harsh environments with satellite connectivity options
RESULTS
40% reduction in equipment failures, 20% increase in productivity
CASE STUDY
Coal India reduced conveyor belt failures by 55% using predictive analytics

Aviation

CHALLENGE
Aircraft maintenance delays cost airlines ₹50,000-2 lakhs per hour
SOLUTION
Predictive maintenance for ground support equipment and facility systems
RESULTS
30% reduction in maintenance delays, improved on-time performance
CASE STUDY
IndiGo improved ground equipment availability by 18% through predictive maintenance

Steel & Metals

CHALLENGE
Furnace and rolling mill failures can halt production for days
SOLUTION
High-temperature monitoring with specialized sensors for extreme environments
RESULTS
35% reduction in critical equipment failures, improved product quality
CASE STUDY
JSW Steel prevented 12 major furnace failures, saving ₹8Cr annually

Technical Specifications

Enterprise-grade technology stack designed for industrial environments

Sensor Specifications

Vibration: ±16g, 10kHz frequency response
Temperature: ±0.1°C accuracy, -40°C to +125°C
Pressure: 0-10,000 PSI, ±0.25% accuracy
Current: 0.1A to 6000A, ±1% accuracy
Battery Life: 5+ years (vibration sensors)
Wireless Range: Up to 1km line-of-sight

Connectivity Options

Primary: LoRaWAN 868MHz/915MHz
Backup: 4G LTE Cat-M1/NB-IoT
Local: WiFi 802.11ac, Ethernet
Industrial: Modbus RTU/TCP, OPC-UA
Satellite: Iridium (remote locations)
Mesh: Self-healing sensor networks

Data Management

Local Storage: 16GB edge processing
Cloud Storage: Unlimited with 99.9% uptime
Data Retention: 5 years historical data
Sampling Rate: Up to 25.6kHz per channel
Compression: 10:1 lossless compression
Backup: Automated daily backups

Security & Compliance

Encryption: AES-256 end-to-end
Authentication: Multi-factor authentication
Compliance: ISO 27001, SOC 2 Type II
Network: VPN and firewall protection
Access Control: Role-based permissions
Audit: Complete activity logging

Processing Power

Edge CPU: ARM Cortex-A72 quad-core
Cloud: Auto-scaling compute resources
AI Processing: GPU-accelerated ML models
Real-time: <100ms alert response time
Throughput: 10,000+ sensors per gateway
Redundancy: Failover and load balancing

User Interface

Web Dashboard: Responsive HTML5 interface
Mobile Apps: iOS and Android native
API: RESTful with comprehensive documentation
Integrations: 50+ pre-built connectors
Customization: White-label options available
Languages: Multi-language support

Proven Maintenance Optimization

Measurable improvements in equipment reliability and maintenance efficiency

40-65%

Reduction in unplanned downtime

25-40%

Decrease in maintenance costs

95%+

Failure prediction accuracy

3-8 months

Typical payback period

15-25%

Extension in equipment life

30-50%

Improvement in OEE

"The predictive maintenance solution transformed our operations. We prevented 8 critical failures in the first year, saving over ₹2.5 crores in production losses. The AI accuracy is remarkable - it predicted a bearing failure 6 weeks before it would have occurred, allowing us to schedule maintenance during planned downtime."
Rajesh Kumar
Rajesh Kumar
Plant Manager
Tata Steel

Calculate Your Maintenance Savings

Get a personalized ROI estimate based on your facility's specific parameters

Production losses from unplanned downtime

Current maintenance and repair costs

Number of machines to monitor

Overall Equipment Effectiveness

Your Estimated Savings

₹684,375
Monthly Savings
₹8,212,500
Annual Savings
₹1,875,000
System Investment
3
Payback (Months)

ROI: 438% annually

Predictive Maintenance Plans

Scalable solutions designed to grow with your maintenance optimization needs

Starter
₹1****/month
Setup: ₹1****

Essential predictive maintenance for small facilities

  • Up to 25 machines monitored
  • Basic vibration and temperature analysis
  • Email and SMS alerts
  • Monthly performance reports
  • Standard dashboard access
  • 8x5 technical support
  • Basic mobile app access
  • 6-month data retention
Limited-time offer: Get 20% off setup
30-day money-back guarantee
Most Popular
Professional
₹2****/month
Setup: ₹2****

Advanced predictive analytics for medium facilities

  • Up to 100 machines monitored
  • Multi-parameter analysis (vibration, temp, pressure)
  • AI-powered failure prediction
  • Real-time mobile alerts
  • Custom dashboard configuration
  • 24/7 technical support
  • Advanced mobile app features
  • 2-year data retention
  • CMMS integration
  • Quarterly optimization reviews
Limited-time offer: Get 20% off setup
60-day money-back guarantee
Enterprise
₹2****/month
Setup: ₹2****

Complete maintenance optimization for large facilities

  • Unlimited machines monitored
  • Advanced AI models with custom training
  • Multi-site management dashboard
  • Custom integrations and APIs
  • Dedicated customer success manager
  • On-site training and support
  • White-label mobile applications
  • Unlimited data retention
  • Advanced analytics and reporting
  • Predictive spare parts management
  • Custom ML model development
  • SLA guarantees and penalties
Limited-time offer: Get 20% off setup
90-day money-back guarantee

Need a custom solution for your specific requirements?

Frequently Asked Questions

Comprehensive answers to common questions about predictive maintenance implementation

Ready to Transform Your Maintenance Strategy?

Join 500+ companies that have reduced downtime by 50% and maintenance costs by 35% with our AI-powered predictive maintenance solution.Get started with a free assessment today.

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