Predictive maintenance deployments

Domtar monitors equipment at its Kingsport, Tennessee mill with 748 Waites AI-assisted vibration sensors, with a Waites analyst and the mill reliability team reviewing alerts.

Stated result 1,546.65 hours of unplanned downtime saved, as estimated by Domtar's reliability superintendent.

Welsh Water signed a three-year agreement running until 2029 for Samotics SAM4 monitoring of critical wastewater assets; the system has monitored a selection of its assets since 2022.

Anglian Water extended its condition monitoring framework with Samotics by two years; SAM4 monitors more than 250 clean water assets and will cover new Strategic Pipeline Alliance pumping stations.

Spot runs thermal, ultrasonic and visual inspection routes on the four bottling lines at the Coca-Cola Europacific Partners plant in East Kilbride, feeding findings to the maintenance system.

Stated result Found a couple of air leaks on site that engineers then inspected and resolved.

Cadillac Casting replaced manual vibration routes with Tractian continuous monitoring on critical assets at its 280,000 square foot foundry in Michigan.

Stated result Bearing wear caught on a 200 HP motor, which was swapped over a weekend before failure.

Yorkshire Water has around 2,500 pumping assets monitored by Samotics SAM4 electrical signature analysis and is adding 1,200 sewage pumping station assets and 300 clean water pumping assets.

Stated result 726 developing faults detected, 40 pollution events prevented and £12.87 million confirmed detection value across the partnership, per Samotics.

Ørsted is piloting ABB's AI-based fault prediction at Avedøre Power Station: data from ABB protection relays and the centralized control system is analyzed to spot early signs of electrical faults.

US Farathane went live with KCF SMARTdiagnostics across its injection molding facilities in 2025, including Georgetown, Texas.

Stated result Enterprise-wide gains by Q1 2026 about three times those of the second half of 2025, per the source.

A Unilever food plant in Latin America deployed Tractian condition monitoring from June 2025: 320 sensors on 40 critical assets, with expansion to 520 sensors planned.

Stated result 19 failures prevented and 117 hours of unplanned downtime avoided in 112 days; over $796K in corrective costs protected.

Danone implemented Tractian condition monitoring on critical assets of a dairy plant, such as homogenizers, pumps and compressors.

Stated result One homogenizer alert avoided up to $40,000 in maintenance costs and an estimated $120,000 to $600,000 in commercial impact.

Aker BP launched a program to deploy AI-driven anomaly detection on equipment such as wells and heat exchangers, feeding data from Cognite's platform into NVIDIA NV-Tesseract models.

Pirelli deployed Tractian condition monitoring sensors on critical assets at a tire plant with 2,800 people, with weekly monitoring reviews.

Stated result 98% alert check-in rate; 77 failures identified; no recorded breakdowns on monitored exhaust systems since deployment.

Whirlpool installed Tractian condition monitoring sensors on critical machines at an appliance plant and prioritizes maintenance by failure risk.

Stated result $1M+ in avoided costs; 95% coverage of previously unmonitored vibration points; 85% insight validation rate.

Southern Water signed a six-year framework with Samotics after a one-year trial; SAM4 monitors 1,458 wastewater and clean water assets on around 600 sites in southern England.

Stated result 63 equipment failures detected during the one-year trial, avoiding an estimated £5 million in equipment damage and penalties.

BlueScope uses Siemens Senseye Predictive Maintenance at steel plants in Australia, including Springhill Works in Port Kembla, and at sites in New Zealand and Southeast Asia.

Stated result About 2,000 hours of unplanned downtime avoided over three years; 53 complete process interruptions prevented

KCF's SMARTdiagnostics flagged rising vibration on an extruder motor at SABIC's Bay St. Louis plant; the cause was traced to a clogged filter and a product change.

Stated result An estimated 8 hours of downtime and $107,000 in losses avoided.

Since mid-2024 the Cargill Amsterdam Multiseed plant has run a pilot with Spot for routine maintenance inspections and visual safety checks in its oilseed crush and refinery plant.

Sachsenmilch ran a pilot of Siemens Senseye Predictive Maintenance with Siplus CMS 1200 vibration monitoring at its Leppersdorf milk processing plant.

Stated result Early detection of a faulty pump saved a low six-figure sum

Nutrien uses Emerson AMS Device Manager and Fisher ValveLink diagnostics with remote monitoring by Spartan Controls to spot failing valves and instruments at its potash mines, on more than 3,500 devices.

Stated result About $7.6 million saved over about six years

AbbVie monitors steam traps at its Illinois campuses in real time with Emerson Rosemount 708 wireless acoustic transmitters and Plantweb Insight software, replacing the annual plant-wide audit.

Stated result $214,000 in cost avoidance over two years; maintenance rounds reduced by 445 hours

Petrobras monitors 114 pressure safety valves and six steam traps at its RPBC refinery with Emerson wireless acoustic transmitters and Plantweb Insight analysis software to trace leaks behind flaring.

Stated result Leaks identified equal to 20,000 metric tons of CO2 equivalent over six months; $220,000 saved

After a pilot on 40 machines at its Fiberon plant in North Carolina, Fortune Brands Innovations is rolling out Augury Machine Health to 1,000 machines across 16 sites in the U.S., UK and Mexico.

Stated result 2.5x ROI in eight months at the pilot site; deployed on two-thirds of the targeted machines at the halfway mark.

Ingredion rolled out Tractian vibration sensors and AI diagnostics for real-time condition monitoring at key plants, including North Kansas City.

Stated result $1.0M in production savings and $223K in maintenance savings at one facility; up to 168 hours of downtime avoided.

Tate & Lyle monitors 280+ critical assets, including fermenter agitators, with Tractian vibration sensors and AI diagnostics at its San Diego facility.

Stated result $446.9K total cost savings, including $380K in production uptime; 84 hours of downtime avoided.

Daikin and Hitachi began a trial of a generative AI agent for equipment fault diagnosis at Daikin's Rinkai commercial air conditioner factory in Sakai, Osaka.

Stated result Earlier proof of concept: cause and countermeasures answered within 10 seconds with over 90% accuracy.

Iron-ore pellet maker Bahrain Steel is adopting Nanoprecise energy-centered predictive maintenance, with a dashboard for energy use and machine health anomalies.

POSCO uses Spot with a thermal camera for blast furnace inspections at Gwangyang Steelworks, running two Autowalk missions around the furnace several times a day.

Glass maker Vivix built an industrial data foundation with HighByte Intelligence Hub and AWS for maintenance operations across its plants in Brazil, and is adding generative and traditional AI.

Fiberglass insulation maker AFICO, a Zamil Industrial subsidiary, is adopting Nanoprecise IoT sensors and AI for machine health and energy monitoring in its manufacturing operations.

Power plant operator NAES signed a multi-year agreement worth more than $100 million with Gecko Robotics to modernize U.S. power plants with robots and AI.

Chilean water utility Aguas Andinas installed Samotics electrical signature analysis monitoring on its critical pumps in Santiago; results of the project are still to come.

After a pilot in 2024, ink maker INX International implemented AssetWatch condition monitoring at four U.S. manufacturing facilities and plans a North America rollout.

Italian water utility Gruppo SMAT launched a pilot of Samotics SAM4 electrical signature analysis on water infrastructure assets; installation took four weeks and data collection has begun.

Boise Cascade scaled AssetWatch wireless vibration monitoring from 1 to 17 wood products manufacturing sites between November 2023 and December 2024, covering 362 assets.

Stated result 130 documented saves and $4M in estimated cost avoidance at the 13-month mark; 5x ROI.

Copper miner Freeport-McMoRan signed a contract with Gecko Robotics and is to start using its robots to generate data for machine-learning algorithms at its operations.

Plastic film recycler Circulus uses Augury Machine Health in its plants to move from reactive to predictive maintenance.

Stated result Average uptime up from around 65 to 70% to 85 to 90%, per the CEO.

After a first pilot phase, ADNOC Gas signed a multi-year contract, at an estimated ceiling of $30 million, to deploy Gecko's wall-climbing robots and Cantilever platform across its sites.

Stated result Pilot phase: asset coverage up 99.6%, efficiency up more than 93% versus manual processes

Owens Corning uses Waites wireless vibration and temperature sensors at its Tessenderlo plant, where an alert on Ball Mill #5 exposed a cracked shaft; the program covers 24 facilities.

Stated result 5,376 hours of downtime and over $11 million in costs avoided on the ball mill, per the Waites case study.

Arbec deployed AssetWatch continuous vibration monitoring on its oriented strand board lines from early 2024, starting with 200 sensors per plant.

Stated result 15 equipment failures prevented in the first six months; 12x six-month ROI.

Under a three-year partnership, Gecko Robotics' data-collecting robots and Cantilever platform are to be deployed at the 80-MW Grant Town coal refuse power plant to reduce forced outages.

thyssenkrupp Steel monitors conveyor rolls of its Duisburg hot rolling mill with Samotics SAM4 Health; after a pilot on 100 rolls it extended use and integrated it into its maintenance process.

Stated result Faults including mechanical unbalance and bearing degradation detected early in the pilot; affected machines replaced before failure (no figures given).

London Stansted Airport selected Samotics SAM4 Health to monitor baggage handling equipment; the system is to be rolled out to dozens of baggage handling systems in arrival and departure halls.

Water utility Dublin San Ramon Services District monitors pumps and blowers with Petasense wireless Vibration Motes, kept in use after an initial pilot at its Dublin, California facilities.

Stated result Nearly 86% less spent on equipment repairs than typically allocated, per the Petasense case study.

South East Water is running a 12-month proof-of-value trial of Samotics SAM4 on drinking water assets, including partially submerged borehole pumps, plus SAM4 Energy for efficiency insights.

Kerry Group started AssetWatch continuous vibration monitoring on roughly 20 critical assets with about 100 sensors, including fluidizing dryers and blowers.

Stated result Three issues caught in the first 2 months; an estimated $43,000 in avoided costs.

Methanex feeds AVEVA PI System data through CONNECT into a time-series foundation model to forecast steam turbine discharge pressure at one site, and into AI agents that assist operators.

Minerals producer Omya uses AVEVA Predictive Analytics in a centralized predictive maintenance program that monitors equipment variables in real time across its plants.

Stated result 15,000 hours of downtime avoided in the first two years; issues detected up to three months ahead

Steelmaker Çolakoğlu Metalurji applies AVEVA Predictive Analytics, fed by SCADA and wireless sensor data, to anomaly detection on its two melt shop cranes.

Stated result about 350 tons of steel production loss prevented; unexpected crane wheel failures reduced to nearly zero

Octapharma runs an IT/OT blueprint project in Stockholm with OEE monitoring on Siemens Industrial Edge and Senseye predictive maintenance in the cloud, and seeks to scale it.

New Enterprise Stone & Lime expanded KCF monitoring equipment after pilots at one aggregate plant and one asphalt plant.

Stated result About 2,000 triggers and 100 actionable insights in six months.

During a 30-day pilot, KCF's SMARTdiagnostics caught an over-greased dryer motor bearing at Altoona Water Authority's wastewater facility.

Stated result $14,904 saved in the first 30 days of the pilot.

Anchor Glass uses KCF's predictive maintenance platform, with sensors on critical equipment, across its five glass container facilities.

Stated result Two saves in the pilot avoided an estimated $200,000 of downtime.

Nabors ran a 5-month trial of KCF vibration sensors on drilling rig mud pumps: 96 sensors on 12 mud pumps across 4 rigs in Texas.

Stated result $320,000 in equipment costs avoided during the pilot.

Georgia-Pacific has deployed 62,000 sensors across more than 100 sites since 2017 and uses KCF's remote monitoring tools with its own support center.

Stated result 50% reduction in unplanned events.

RYAM piloted KCF sensors at one facility in early 2021 and expanded to all sites; its Jessup facility has approximately 2,600 sensors on about 95% of critical machinery.

Tata Steel Nederland uses Siemens Senseye Predictive Maintenance at the Coldmill Annealing Bay of its IJmuiden steel plant to warn maintenance teams of emerging equipment issues.

Stated result Equipment breakdowns reduced by 67%

Třinecké železárny piloted the Siemens Predictive Service Analyzer on an edge device to monitor the Sinamics S120 drives of the sizing mill at its Ostrava tube mill.

Koppers monitors seven critical hot-oil pumps at an unstaffed pumping facility with two Emerson AMS Asset Monitors, whose edge analytics identify faults and recommend maintenance actions.

Stated result Two pumps changed out after the monitors flagged them; significant wear found in carbon bushings

DuPont moved from route-based to predictive maintenance with Augury Machine Health at proof-of-concept sites and is rolling it out across its businesses.

Stated result 7x ROI at the proof-of-concept sites in less than a year.

Osem-Nestlé has used Augury Machine Health since 2020 to avoid unexpected downtime; one alert on its Sabra hummus line allowed an early repair.

Stated result One early repair avoided a shutdown of the entire factory, per the source (no figures given).

Worthington Steel installed AssetWatch vibration sensors across its hot-dipped galvanizing plant near Toledo; an early furnace roll bearing detection allowed a planned replacement.

Stated result 18% less machine-related downtime and 17% fewer reworks; about 48 hours of downtime and $500k in lost gross margin avoided on one bearing.

After a first deployment in Columbus, OH, Worthington Steel expanded AssetWatch monitoring to 17 steel processing and pressure cylinder facilities in North America.

Stated result More than 1,800 sensors on 650+ machine assets; 260+ downtime risks resolved; $16M+ in potential lost gross margin saved.