Part-level failure prediction for a packaging machine builder
Sensors and models that name the failing part before the line stops.
Phase one dashboard on simulated data, as labeled on screen. Client logo blurred.
The problem
A rotary filler builder has about 250 machines running in customer plants. When a part fails, the line stops and the repair can run into six figures. There was no early warning.
What we built
Heat, pressure and temperature sensors on the fillers, plus a camera where visual wear says more than a probe. Models that predict wear on specific parts, checked against faults we introduce on purpose before anyone relies on them.
What changed
Service gets planned ahead of a breakdown instead of after it. The builder can extend the same system across its installed base.
- machines in the installed base
- ~250
- machines on the platform today
- 12
- prediction, not whole machine
- Part level
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