CASE STUDY

Predictive Maintenance in a Manufacturing Plant Using an AI-Powered Digital Twin

Industry

Manufacturing (Automotive Components) 

Ecosystem

SAP

Metrics

    45% Downtime Reduction, 25% Maintenance Cost Savings, 12% Scrap Rate Reduction 

    Business Challenge 

    A global automotive component supplier struggled with escalating unscheduled downtime and inefficient, reactive maintenance stemming from outdated time-based schedules across a mix of legacy and modern equipment. This resulted in significant financial losses due to production disruptions and penalties, increased maintenance costs from emergency repairs, inconsistent product quality leading to dissatisfied customers, and growing safety risks for plant personnel – necessitating a strategic shift toward automation, optimized maintenance processes, and comprehensive visibility to transform maintenance into a driver of efficiency and profitability. 

    Solution Implemented 

    UCBOS implemented an AI-driven predictive maintenance solution integrated with existing IIoT sensor network, cloud-based data platform, and ERP/CMMS systems. Our experts leveraged data from the production line’s existing sensor network, analyzing real-time information with AI to predict equipment health and possible maintenance: 

    • Intelligent Anomaly Detection: Utilized AI-powered algorithms to identify subtle deviations from normal operating conditions based on sensor data (vibration, temperature, pressure, etc.), flagging potential equipment failures before they occurred. 
    • Predictive Failure Modeling: Built predictive models based on historical maintenance data, equipment specifications, and real-time sensor readings to forecast the remaining useful life of critical components. 
    • Automated Maintenance Recommendations: Developed automatically generated prescriptive recommendations for maintenance actions, like part replacements, lubrication adjustments & operational parameter optimizations, based on the predicted failure modes.  
    • Dynamic Scheduling & Work Order Management: Integrated CMMS enabling automated work order creation and scheduling based on the predictive maintenance recommendations. The system dynamically adjusted maintenance schedules based on real-time equipment health and production demands. The system warns in the event of a Cyber threat on equipment, while adhering to the regulatory standards for the equipment. 
    • Real-time tracking: Engineers can observe equipment in real time and address any urgent issues. 
    • Environmental monitoring: Alerts if the operating environment is outside of normal parameters. 

    This integrated solution created a centralized view of equipment health and maintenance activities, accessible to authorized personnel via dashboards and mobile devices. 

    Business Outcome 

      By leveraging AI-driven Contract Analysis and Automation, UCBOS transformed the contract management process from a manual, error-prone system to a fully automated, data-driven operation. The results were significant: improved efficiency, reduced costs, enhanced compliance, and better business outcomes.  

      • 100% Automation: The manual data entry and spreadsheet tracking were completely eliminated, freeing up staff to focus on more strategic tasks. 
      • 90% SLA Improvement: The automated tracking of key performance metrics and timely alerts enabled the hospital to proactively manage its contracts and ensure compliance with SLAs, resulting in a 90% improvement. 
      • Improved Visibility: The centralized contract repository provided a single source of truth for all contract information, enabling better decision-making and risk management. 
      • Enhanced Negotiation Power: Access to accurate and up-to-date contract data empowered the hospital to negotiate more favorable terms with vendors and partners, resulting in significant cost savings. 

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      UCBOS

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      1675, Terrell Mill Road, Suite 300,

      Marietta, GA 30067, United States

      Phone

      +1(866)818-2267

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