Predictive Maintenance for CNC Machines
Deployed IoT sensors on 200+ CNC machines for a leading automotive parts manufacturer, reducing unplanned downtime by 40% through real-time monitoring and predictive analytics.
The Challenge
A major automotive parts manufacturer was experiencing frequent unexpected machine failures on their production floor. With over 200 CNC machines running continuously, unplanned downtime was causing significant production delays and revenue loss.
The existing reactive maintenance approach meant that failures were only addressed after they occurred, leading to cascading delays across the entire production schedule. The company needed a proactive solution to predict failures before they happened.
Key Pain Points
- 40-60 hours of unplanned downtime per month
- High maintenance costs from emergency repairs
- No visibility into machine health status
- Difficulty scheduling preventive maintenance
Our Solution
IoT Sensor Deployment
Installed vibration, temperature, and acoustic sensors on all 200+ CNC machines to capture real-time operational data.
ML-Based Analytics
Developed machine learning models to analyze sensor data and predict potential failures 7-14 days in advance.
Alert Dashboard
Created a centralized monitoring dashboard with automated alerts for maintenance teams to take proactive action.
Results & Impact
Reduction in Unplanned Downtime
Lower Maintenance Costs
OEE Improvement
Additional Benefits
Ready to Transform Your Operations?
Let's discuss how predictive maintenance can reduce downtime and costs for your manufacturing facility.
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