Industry · Data and Operations

Industrial Predictive Maintenance: Detect Failures Before the Plant Shuts Down

Industrial predictive maintenance connects sensors, maintenance systems, and analytics so that your team can take action when the asset needs it, not when it breaks down.

The Cost of an Unplanned Downtime

Every hour of downtime costs twice as much: in lost production and in emergency repairs

According to Siemens, unplanned downtime costs the world’s 500 largest companies 11% of their revenue—nearly $1.4 trillion a year (The True Cost of Downtime 2024). Calendar-based predictive industrial maintenance replaces parts that are still in good condition while overlooking those that are already failing. Meanwhile, asset data resides in the plant (OT) and work orders in another system (IT), with no connection between them. The result is a maintenance decision made based on information that arrives too late.

How we’ll handle it

Industrial Predictive Maintenance: From Asset Data to Decision-Making

We start with what you already have: PLCs, SCADA, data loggers, your maintenance system, and your Microsoft licenses. We don’t replace just for the sake of replacing. For industrial predictive maintenance, we integrate IT/OT convergence and feed the data into analytics and data governance so that alerts reach the right people who can take action.

Data logging: vibration, temperature, and current

Early-Warning Models for Critical Assets

Asset Health Dashboard for the Plant and Management

Work order generated from the alert

Tablero de salud de activos para mantenimiento predictivo industrial

What’s Included

Concrete deliverables, not just another dashboard

Criticality Assessment

Which assets are causing the plant to shut down, what data do you have today on each one, and where to start.

IT/OT Data Architecture

How data travels from the sensor to the maintenance system using your current infrastructure.

Asset Health Dashboard

Status, trends, and alerts by equipment—all in one place for operations, maintenance, and finance.

Alert Rules and Templates

Thresholds and models tailored to each asset, with periodic review of false positives.

Integration with the work order

The alert creates the work order in your maintenance system without requiring any manual data entry.

Team Training

Their staff learns to interpret the alerts and adjust the rules; the knowledge stays within the plant.

How We Work

Four-phase industrial predictive maintenance, with before-and-after measurements

If you didn’t cross the finish line, it doesn’t count as a result.

01

Diagnosis

We identify the critical assets and the data that already exist.

02

Design

We define sensors, integration, and alert rules.

03

Implementation

We are launching a pilot program for an asset or a line.

04

Re-measurement

We measure avoided downtime and costs against the baseline.

Where it applies

Same method, assets in each sector

Mining

Mills, pumps, and conveying equipment where a single stoppage brings the entire chain to a halt.

Energy and Utilities

Distributed assets and service continuity as a priority.

Pulp and paper

Continuous processes in which vibration and temperature indicate impending failure.

Chemicals

Reactors, pumps, and valves with strict safety requirements.

Food and beverages

Packaging and refrigeration lines where a stoppage compromises the product.

All industries

See the range of industries we serve and learn how to get started in yours.

Triple Impact

Profitability, sustainability, and talent all in one project

Profitability

Fewer unplanned shutdowns and fewer unnecessary replacement parts.

Sustainability

Less waste of parts and energy. Every improvement is reported along with its metrics—no empty promises.

Talent

The technician shifts from putting out fires to planning the operation.

Frequently Asked Questions

Frequently Asked Questions

{“@context”: “https://schema.org”, “@type”: “FAQPage”, “mainEntity”: [{“@type”: “Question”, “name”: “¿Qué es el mantenimiento predictivo industrial y en qué se diferencia del preventivo?”, “acceptedAnswer”: {“@type”: “Answer”, “text”: “El mantenimiento predictivo industrial interviene según la condición real del activo, medida con datos como vibración, temperatura o corriente. El preventivo interviene por calendario, haya o no desgaste.”}}, {“@type”: “Question”, “name”: “¿Necesito cambiar mis sensores o mi sistema de mantenimiento?”, “acceptedAnswer”: {“@type”: “Answer”, “text”: “No necesariamente. Partimos de lo que ya tiene y solo añadimos sensores donde el diagnóstico muestre un vacío en un activo crítico.”}}, {“@type”: “Question”, “name”: “¿Cuánto tarda el primer piloto?”, “acceptedAnswer”: {“@type”: “Answer”, “text”: “Depende del activo y de los datos disponibles. El diagnóstico define el alcance y el plazo antes de comprometernos.”}}, {“@type”: “Question”, “name”: “¿Qué activos conviene monitorear primero?”, “acceptedAnswer”: {“@type”: “Answer”, “text”: “Los que más cuestan cuando paran: los que detienen la línea completa, tienen repuestos de entrega lenta o riesgo de seguridad.”}}, {“@type”: “Question”, “name”: “¿Cómo se mide el retorno?”, “acceptedAnswer”: {“@type”: “Answer”, “text”: “Con una línea base antes del piloto y una re-medición después: paradas evitadas, horas de mantenimiento correctivo y costo por activo.”}}]}

Diagnosis

Which asset costs you the most when it stops?

We help you prioritize predictive industrial maintenance by establishing a baseline and conducting a measurable pilot project.

Keep exploring

Connect with

Data and Analytics

Dashboards that management actually uses.

IT/OT Convergence

Operations and the business both focus on the same data.

Field Operations

Field maintenance and operation.

Industries

The eight sectors we serve.

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