Your next breakdown is already making noise: an interactive predictive maintenance demo
A simulated cooling water pump runs with vibration, bearing temperature and motor current sensors. A bearing starts to wear, the trend rises, an alert arrives with hours to spare, and you decide: repair at the planned stop, or keep running and see what an unplanned failure costs.
Every number, ID and event in this demo is simulated to show how the system behaves. None of it is customer data or a measured result.
What you are looking at
- Normal running: three sensors stream from the pump; the health score sits near 100.
- Early wear: vibration creeps up while still inside limits, the stage nobody on the floor notices.
- Alert and diagnosis: vibration crosses the warning limit and the pattern points at the drive end bearing. The planner is notified.
- Your decision: raise a work order for the planned stop, or keep running.
- Work order and repair: the technician scans the QR on the pump, opens the video SOP and replaces the bearing.
- Outcome: planned and unplanned downtime side by side. Replay and choose the other way to compare.
How this maps to a real system
We start with the few machines whose failure stops production, fit sensors or read the signals the PLC already has, and set limits from each machine’s own baseline rather than a generic number.
Alerts become work orders in the maintenance system you use, and technicians get the asset history and SOP on a phone at the machine.
From real projects
Our QR based maintenance and video SOP systems support blast furnaces, coke ovens, rolling mills and processing lines, with more than ₹80,000 crore (about US$9.6 billion) of machinery under maintenance.
Company reported project figure, not independently audited, not a promise for another site.
Questions
How does predictive maintenance know a machine will fail?
Most mechanical faults change how a machine vibrates, heats up or draws current well before it stops. Sensors measure these continuously, and the trend is compared with limits and known fault patterns, so a planner gets a warning with time left to act.
Which sensors are used?
Usually vibration and temperature sensors on bearing housings, plus motor current from the drive or a clamp sensor. Existing PLC and SCADA signals are used where they are already available.
Is the data in this demo real?
No. The pump, readings, limits, alert time and repair hours are simulated to show how the system behaves. They are not customer data or a measured result.
What happens after an alert?
A work order is raised for the next planned stop, the spare is reserved, and the technician scans a QR code on the machine to open its history and the video SOP for the job.
Why does the demo ask for my name and email?
So an engineer can follow up if you want to talk about your own machines. The explanation on this page is open to everyone; only the interactive view needs the form, once for all six demos.
Free scoping call. We start with one line, never change your machine logic, and you own the code and the data.