Predictive maintenance — Paper mill
Vibration, current and thermal models that predict failures days ahead. Delivered for a paper mill client in Bhavnagar.
- Location
- Bhavnagar
- Year
- 2020
- Duration
- 12 weeks
- Team
- 13 engineers
- 51%
- fewer breakdowns
- 8.3
- days warning
- −32%
- maintenance cost
The challenge
The paper mill team was relying on manual effort that could not keep up with volume, and every miss had a direct cost.
What we built
Built in our Motera lab, validated on a replica rig, then commissioned on site in days using scikit-learn and InfluxDB.
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
- Remote monitoring and over-the-air updates included
- Operator training delivered in Gujarati, Hindi and English
- Documentation, drawings and source handed over at close
- Integrated with existing PLC, ERP or GIS systems — no rip-and-replace
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