Predictive maintenance — Cement
Vibration, current and thermal models that predict failures days ahead. Delivered for a cement client in Morbi.
- Location
- Morbi
- Year
- 2026
- Duration
- 14 weeks
- Team
- 6 engineers
- 54%
- fewer breakdowns
- 5.3
- days warning
- −17%
- maintenance cost
The challenge
Conditions on site — heat, dust, vibration and patchy connectivity — had defeated two earlier attempts at this in cement.
What we built
We ran a two-week discovery sprint, then built and fielded the system end to end on scikit-learn, XGBoost and InfluxDB, with operator training and an SLA.
Delivery timeline
Phase 1
Discovery sprint and site survey
Phase 2
Prototype built and tested in the Motera lab
Phase 3
Pilot on site with before/after measurement
Phase 4
Scale-out, training and handover
Highlights
- Before-and-after measurements agreed with the client up front
- Safety case reviewed with the client's EHS team
- Designed, built and supported from Motera, Ahmedabad
- Operator training delivered in Gujarati, Hindi and English
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