Predictive Maintenance

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Discover how other companies in our network use predictive maintenance to identify problems early on—before they lead to downtime. Could a spike in voltage be an early warning sign of a malfunction?

IIoT Success Stories from Practice

Companies from our network that have already successfully implemented this use case

Hüdig GmbH & Co. KGVGH VersicherungenRail Cargo GroupSociété Nationale des Chemins de Fer LuxembourgeoisAurubis AGSPALECK GmbH & Co. KGHitachi Construction MachineryGlobalFoundriesNovofermifm-UnternehmensgruppeTetra PakKROHNE Messtechnik GmbHERA AdvancedWAGO GmbH & Co. KGZF Friedrichshafen AGZEISS MicroscopyTofaşBSHKAEFERGHD Georg Hartmann MaschinenbauJansen ToreMercedes-Benz Group AGWoodward Kempen GmbHDoepke Schaltgeräte GmbHEUROGATEBremboNowy Styl Sp. z o.o.CURRENTABESI Marine Systems GmbHStadtwerke PyrmontHüdig GmbH & Co. KGVGH VersicherungenRail Cargo GroupSociété Nationale des Chemins de Fer LuxembourgeoisAurubis AGSPALECK GmbH & Co. KGHitachi Construction MachineryGlobalFoundriesNovofermifm-UnternehmensgruppeTetra PakKROHNE Messtechnik GmbHERA AdvancedWAGO GmbH & Co. KGZF Friedrichshafen AGZEISS MicroscopyTofaşBSHKAEFERGHD Georg Hartmann MaschinenbauJansen ToreMercedes-Benz Group AGWoodward Kempen GmbHDoepke Schaltgeräte GmbHEUROGATEBremboNowy Styl Sp. z o.o.CURRENTABESI Marine Systems GmbHStadtwerke Pyrmont

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Bolt Monitoring in Predictive Maintenance

Implemented under NDA – user company confidential
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Early Detection of Damage in Predictive Maintenance

32 Solution Examples

With modern sensor technology and smart data analysis, you can detect damage before it escalates. Whether it involves leaks in water pipes, overheating in electrical systems, or mechanical wear – continuous monitoring makes it possible to identify problems early and take targeted action. This not only saves costs but also protects your assets and infrastructure in the long term.

Implemented under NDA – user company confidential
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Leak Detection in Predictive Maintenance

4 Solution Examples

Leakage Detection (Air) Sensors detect air leaks in compressed air systems and machinery. Continuous monitoring enables the localization of losses and the initiation of targeted corrective measures. Leakage Detection (Gas) Sensors identify gas leaks in pipelines and systems. Permanent monitoring supports safe operation and reduces unplanned downtime. Leakage Detection (Water) Sensors detect water escaping from systems and pipelines. Deviations in water flow are identified early to prevent damage and downtime.

Implemented under NDA – user company confidential
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Acoustic Monitoring in Predictive Maintenance

3 Solution Examples

Detecting anomalies through noise patterns. Acoustic sensors diagnose wear and malfunctions in machines based on sound patterns. This precise method reduces unplanned downtime and ensures efficient maintenance planning.

Implemented under NDA – user company confidential
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Moisture Measurement in Predictive Maintenance

4 Solution Examples

Humidity measurement captures ambient conditions in the form of relative humidity and its changes over defined time periods. It is used to monitor air conditions even in hard-to-reach or non-visible locations.

Implemented under NDA – user company confidential
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Filter Monitoring in Predictive Maintenance

3 Solution Examples

Efficient maintenance of filter systems. By monitoring pump and fan systems, maintenance events can be predicted and optimized. Sensors capture the status of filter mats or wear data, enabling proactive planning of service interventions.

Implemented under NDA – user company confidential
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Cable and Chain Monitoring in Predictive Maintenance

10 Solution Examples

Cable and chain monitoring detects breaks, abrasion, and structural changes in cables and chain links based on movement anomalies and physical measurements. Parameters monitored include tensile and compressive forces, bending radii, insulation resistance, temperature, current, and vibration events.

Implemented under NDA – user company confidential
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Tension/Thrust Monitoring in Predictive Maintenance

6 Solution Examples

Digital systems for tension and thrust force monitoring detect mechanical anomalies early to prevent downtime and damage. Integrated into machine controls, they enable immediate responses, protecting processes and assets.

Implemented under NDA – user company confidential
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Temperature Measurement in Predictive Maintenance

9 Solution Examples
Implemented under NDA – user company confidential
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Groundwater Level Measurement in Predictive Maintenance

Precise level measurement without maintenance effort! Battery-powered sensors automatically record groundwater levels, for example – even in hard-to-reach areas. The maintenance-free technology enables efficient and reliable data collection.

Implemented under NDA – user company confidential
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Vibration Monitoring in Predictive Maintenance

12 Solution Examples

Precise diagnostics through vibration analysis. Monitoring bearings or heat treatment furnaces provides early warning signals for temperature deviations or mechanical irregularities. This ensures production quality and prevents damage.

Implemented under NDA – user company confidential
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Break Detection in Predictive Maintenance

5 Solution Examples

Detect damage before it gets costly. Breaks or cable stress occur unexpectedly – with serious consequences for production and asset availability. Condition monitoring systems for break detection continuously monitor critical movements and report the smallest deviations in real time. This prevents consequential damage and enables targeted maintenance planning.

Implemented under NDA – user company confidential
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Industry Challenges – Do These Sound Familiar?

Typical Challenges in Predictive Maintenance

  • How do I identify the optimal time for maintenance measures?
  • How do I efficiently process large volumes of data to generate meaningful forecasts?
  • How do I find technologies and partners who have successfully implemented predictive maintenance?

Our platform is your shortcut to the solution. We show you how other companies use predictive maintenance to reduce costs and maximise asset availability. Find vetted technologies and partners that bring your projects to success – quickly and efficiently.

Benefits of Predictive Maintenance

Benefits of Predictive Maintenance: Prevent Failures, Increase Efficiency

Prevention of Unplanned Failures

Predictive maintenance minimises the risk of unplanned machine downtime through continuous monitoring of critical components. Sensors and data analysis identify anomalies at an early stage so that potential failures can be prevented proactively.

Optimised Planning and Resource Deployment

Using condition data, maintenance can be planned precisely. Spare parts, personnel and production time windows are coordinated efficiently, leading to optimised resource utilisation and significant savings.

Cost Savings Through Precise Maintenance

Unnecessary maintenance work is eliminated, as interventions only take place when the actual condition of the machine requires it. This significantly reduces both direct maintenance costs and downtime.

Extended Machine Lifespan and Performance

Predictive maintenance ensures gentle use of assets. By detecting and addressing wear at an early stage, the lifespan of machines is extended while their efficiency is maintained.

Well-Founded Data-Based Decisions

The continuous collection and analysis of machine data provides a solid basis for strategic decisions. Companies can identify trends, adapt their maintenance strategy and continuously improve production processes.

Sustainability and Efficiency Gains

Through the targeted use of resources and reduction of downtime, predictive maintenance contributes not only to cost reduction but also to more sustainable use of materials and energy.

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