“Standstill is a thing of the past – How an OEM revolutionized its maintenance”
Problem
“Standstill is a thing of the past – How an OEM revolutionized its maintenance”
A leading international car manufacturer was faced with a seemingly paradoxical problem: despite high investments in modern production facilities, unplanned downtimes occurred regularly. Maintenance was based on fixed intervals rather than on the actual condition of the machines. Breakdowns not only cost money, but also jeopardized delivery dates—and thus the reputation of premium brands.
The company decided on a radical approach: moving away from reactive maintenance and toward predictive maintenance. Together with an AI specialist, a predictive maintenance solution was developed that evaluates machine data in real time: vibrations, power consumption, temperature, noise, even micro-deviations in machining processes.
Solution
Sensors were installed on over 800 machines in the European factory network. A central AI model spent months learning the “normal state” of each machine – individually and in great detail. As soon as deviations were detected, the system suggested specific maintenance measures – long before a failure occurred.
Benefit
After only 12 months of operation, the following improvements were documented:
- 37% fewer unplanned downtimes
- 21% lower maintenance costs
- 3.4 million euros saved in the first year
- 98% schedule adherence to production deadlines
Particularly noteworthy: Die Mitarbeiter im Instandhaltungsteam fühlten sich durch die KI nicht ersetzt – sondern aufgewertet. „Früher haben wir Feuerwehr gespielt. Heute sind wir Strategen“, sagte der Wartungsleiter bei einem internen Review.
The learning: Predictive maintenance is not an IT project, but a game changer for manufacturing. Knowing when machines will break down gives you control over costs, schedules, and quality. Success depends not only on technology, but also on the interaction between data, acceptance, and integration into everyday work. The champions of the industry have long understood this.
Quote from the project: “We haven't just made our machines smarter – we've revolutionized our entire approach to production.” – Director of Operations, Automotive Europe