Client context
An asset-intensive operation running continuous, multi-shift production across a fleet of critical rotating and process equipment.
Problem size
Thousands of unplanned-downtime hours a year under calendar-based maintenance — either replacing healthy parts early or finding failures after they had already stopped the line.
What KEPLER did
- Engineered a dataset from sensor/SCADA, maintenance-log and work-order history
- Built explainable asset-health models that flagged rising failure risk with a reason code
- Pushed alerts into the CMMS as work orders — not another dashboard to check
- Added a Power BI layer for reliability engineers to track asset health and model performance
Results
30% less unplanned downtime, with fewer premature part replacements and maintenance effort focused where failure risk is highest.
Anonymized client engagement; identifying details withheld for confidentiality.