Predict Machine Failures Before They Happen.
Automate maintenance scheduling, detect machine anomalies, and anticipate equipment failures with AI-powered predictive maintenance solutions for smarter manufacturing.
Turn Machine Data Into Maintenance Decisions
Explore how intelligent automation can help your team identify risks, plan maintenance, and manage work orders more efficiently.
Is Unplanned Equipment Downtime Affecting Your Production?
Traditional reactive and calendar-based maintenance models create blind spots, expensive machine stoppages, and lost throughput across the shop floor.
Unexpected Machine Failures
Equipment breakdowns disrupt production schedules, cause delivery delays, and create urgent, high-cost emergency repair work.
Reactive Maintenance
Teams often respond after a fault occurs instead of planning ahead, leading to repeated firefighter maintenance and accelerated asset wear.
Manual Work Orders
Manual task creation, clipboard sign-offs, and disconnected spreadsheets slow down execution and leave zero audit visibility for engineering heads.
Undetected Machine Anomalies
Early warning signs in temperature drift, vibration peaks, motor current spikes, or hydraulic pressure are easily missed during visual checks.
Unplanned Spare-Part Needs
Unexpected breakdowns make it harder to prepare critical parts in time, leaving expensive production lines halted while waiting for rush deliveries.
Limited Equipment Visibility
Without centralized machine-health telemetry, plant managers cannot objectively prioritize preventative overhaul work before critical shifts.
Make Maintenance Proactive, Not Reactive
Transform machine telemetry into reliable maintenance planning, real-time anomaly alerts, and automated work-order dispatching.
1. Automated Maintenance Scheduling
Schedule maintenance activities, manage due dates, send automatic notifications, and help plant teams coordinate preventative tasks based on calibrated machine run hours, production cycles, and operating conditions.
- Dynamic maintenance calendar synced with shift schedules
- Runtime counter and cycle-based trigger rules
- Automated technician skill matching and job assignment
2. Machine Failure Prediction & Anomaly Detection
Continuously analyze available machine sensor data, vibration harmonics, motor loads, and thermal gradients to flag abnormal equipment behaviour and isolate impending component failure risks before catastrophic damage occurs.
- FFT spectral vibration analysis for bearings and gearboxes
- Thermal runaway and mechanical friction anomaly detection
- Baseline profile training for custom industrial machinery
3. Automated Alerts & Work-Order Generation
Instantly trigger multi-channel alerts when maintenance thresholds are crossed or anomalies are confirmed. Automatically generate digital work orders, pre-fill machine failure codes, and route tickets through configured approval hierarchies.
- Instant SMS, email, and plant floor dashboard notifications
- Automatic bill-of-materials and spare parts hold requests
- Step-by-step digital SOP inspection checklists attached
4. Remaining Useful Life (RUL) Prediction
Where suitable historical records and real-time operational data are available, model equipment wear trajectories to estimate remaining useful life. Empower plant heads to time maintenance interventions during planned factory switchovers.
- Asset degradation curve modeling based on real duty cycles
- Alignment with scheduled factory changeovers and shutdowns
- Optimal replacement timing to prevent premature component scrap
From Machine Monitoring to Actionable Maintenance
A proven, deterministic architecture connecting industrial edge hardware to actionable engineering execution.
Collect Machine Data
Capture continuous readings from machine sensors (vibration, heat, pressure, motor amps), PLC registers, operating logs, and historical work records via standard industrial protocols.
Detect Anomalies & Assess Risk
Algorithmic models evaluate incoming sensor telemetry against established baseline thresholds and equipment operating patterns to isolate early deviations and estimate risk severity.
Trigger Alerts & Work Orders
When an anomaly or service interval is confirmed, the system immediately notifies designated maintenance engineers and automatically creates or routes digital work orders.
Improve Maintenance Decisions
Use equipment-health trends, root-cause analytics, and maintenance history to refine predictive models, align spare-part stocking, and optimize future planned maintenance windows.
Improve Equipment Reliability With Intelligent Automation
Deliver tangible operational efficiency for plant heads, maintenance managers, and operations directors.
Reduce Avoidable Downtime
Identify early warning signs in machine vibration and temperatures before failures snowball into unplanned production shutdowns.
Improve Maintenance Planning
Organize preventative schedules, real-time alerts, and work orders in a structured digital workflow with end-to-end accountability.
Optimize Maintenance Resources
Help maintenance crews prioritize critical machines, eliminate unnecessary manual inspections, and allocate technical hours effectively.
Improve Asset Visibility
Make real-time machine health indices, anomaly flags, and work-order statuses easily accessible on central shop floor dashboards.
Support Spare-Parts Planning
Use equipment wear forecasts and failure warnings to stage critical spares in advance, avoiding expensive rush freight or stockouts.
Make Data-Driven Decisions
Rely on validated machine trends, statistical anomaly reports, and remaining useful life estimates to justify asset replacement and CAPEX.
Built Around Your Manufacturing Maintenance Workflow
Engineered to integrate seamlessly with existing shop floor automation, plant controllers, and enterprise software.
Industrial IoT & PLC Native
Directly ingest sensor signals via standard industrial fieldbuses (Modbus TCP/RTU, OPC-UA, MQTT, Ethernet/IP) without disrupting plant PLC logic.
On-Premise & Air-Gapped Ready
Deploy predictive algorithms on edge servers within your local factory LAN. Zero mandatory cloud exposure, ensuring strict manufacturing IP security.
4-Week Feasibility Pilot
Validate anomaly detection accuracy on 2–4 critical machines with dedicated PMDG automation engineers before rolling out across plant lines.
Answers for Engineering & Operations Leaders
Explore Predictive Maintenance for Your Factory
Tell us about your equipment and maintenance challenges. Our industrial automation team will discuss a suitable, validated approach for your plant.
Ready to Prevent Downtime Across Your Manufacturing Plants?
Join the global industrial enterprises leveraging PMDG's predictive maintenance platform to monitor equipment health, eliminate unplanned downtime, and optimize maintenance schedules.
