Reducing Unplanned Downtime by 34% with Predictive Maintenance
A sample engagement showing how sensor telemetry and anomaly detection can cut unplanned stoppages across a multi-site manufacturer.
Unplanned Stoppages Were Draining Output
A mid-sized manufacturer running nine plants saw repeated unplanned stoppages from bearing and motor failures that alarms flagged only after damage began.
Maintenance was calendar-based, so some assets were serviced too early while others failed between visits. Plant managers had no shared view of asset health across sites.
- Alarms triggered after failure had started.
- Calendar-based servicing wasted planned hours.
- No consolidated asset health view across plants.
Edge Telemetry and Anomaly Detection
BEZENT designed a sensor mesh that streams vibration and temperature data to edge gateways, with models scoring each asset’s health in near real time.
Maintenance leads received ranked alerts with a likely cause and recommended window. A single dashboard showed asset health, open work orders and trends for every plant.
- Edge gateways with local inference for low latency.
- Health scoring with explainable alert reasons.
- Work-order integration with the existing maintenance system.
Measurable Gains in Reliability
Within two quarters the pilot plants saw unplanned downtime fall by about a third and maintenance hours shift from reactive to planned work.
The results below are illustrative figures for this sample case study.
- 34% reduction in unplanned downtime at pilot sites.
- 21% fewer emergency maintenance call-outs.
- Rollout to remaining plants planned in phases.
Frequently Asked Questions
Direct answers about engineering methodology, technical tradeoffs, and production implementation.
Ready to discuss your project requirements?
Start a Project →Do you need to replace existing machines?
No. Sensors are retrofitted to existing assets, and gateways connect to current control and maintenance systems.
How long does a pilot take?
A focused pilot on a handful of critical assets typically takes ten to twelve weeks from kickoff to the first live alerts.
Is this a real client engagement?
This page is an illustrative example of the type of work BEZENT delivers; figures are representative, not client-confirmed.
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