Manufacturing · Aegis Industrial
Maintenance that predicts, instead of explaining the outage.
Unplanned downtime down 41% on the pilot line. First-year payback in month seven.
Challenge
A multi-site manufacturer had years of PLC and CMMS data and a graveyard of 'Industry 4.0' slideware. Plant managers did not trust a model they could not interrogate. IT would not open the OT network.
Approach
The audit scored technology higher than change — the reverse of what the last integrator assumed.
We ran the first model on a historian extract in a read-only zone. No OT write-back until operators signed the playbook.
Operators named the failure modes; the model ranked them. That inversion is why it was used.
A 2-day implementation masterclass trained reliability engineers to own the loop after we left.
Outcome
What moved.
Pilot line unplanned downtime dropped 41% in two quarters. A second line followed under the plant's own engineers. The 'AI program' is now a standing item in the weekly production meeting — which is the actual victory.
Client names are used with permission or as published composites. Every figure on this page traces to a specific engagement and can be walked through on a call. Confidential work stays unpublished.
Next step
A similar constraint?
If the problem looks familiar, the discovery call is the right next hour.