Case study
Manufacturing
Production line vibration monitoring pilot
Illustrative pilot scenario based on typical manufacturing engagements. Metrics represent design targets for a scoped pilot—not published results from a named customer.
Photo by Homa Appliances on Unsplash
Situation
A manufacturing site runs a production line where unplanned motor failures on conveyors and auxiliaries cause multi-hour stoppages. Maintenance is largely reactive—issues surface when operators hear noise or production stops.
Task
Design a focused pilot to detect abnormal vibration and temperature trends on the highest-risk motors before failure, without disrupting production or replacing existing automation.
Action
- Instrumented six critical motors with vibration and surface temperature sensors
- Deployed edge gateways for local buffering and threshold pre-processing
- Built maintenance-facing dashboards with trend history and alert context
- Validated alert thresholds with the maintenance team over four weeks of live data
Result
- Maintenance receives early warning days before catastrophic bearing failure in test scenarios
- Inspection can be scheduled in planned windows instead of emergency callouts
- Historical trends support root-cause analysis after process changes
Up to 30% on pilot assets
Target downtime reduction
6 motors, 1 production line
Pilot scope
48–72 hours before failure
Alert lead time goal
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