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Case Studies

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Identify anomalies with real-time sensor analytics

Identify anomalies with real-time sensor analytics

Identify anomalies with real-time sensor analytics

How early detection and adaptive machine learning reformed maintenance efficiency

How early detection and adaptive machine learning reformed maintenance efficiency

Early failure detection

Real-time sensor insights

Scalable, flexible model

Adaptive ML efficiency

The challenge

Predictive maintenance with sensor analytics

A European engineering company collected continuous sensor data from multiple turbines. To enhance efficiency, it aimed to develop an algorithmic workflow for automatic gearbox anomaly detection using sensor data.

Key challenges

  • Integrating data from multiple sensors

  • Predicting machine failures at an early stage

  • Deploying a real-time solution for high-velocity data

The solution

Optimized gearbox monitoring

Data and classification

Analyzed sensor data

Categorized trends patterns

Assessed model performance

Anomaly detection

Dual-model analysis

Filtered false alarms

Score-based detection

Implementation approach

1

Model deployment

  • Seamless rollout

  • High-speed processing

  • Real-time integration

2

Alerts and thresholds

  • Triggered alerts

  • Set detection limits

  • Enabled proactive maintenance

3

Continuous improvement

  • Refined models

  • Adjusted thresholds

  • Help improve accuracy

The impact

Streamlined operations and cost savings

Cost savings

  • Early failure detection

  • Maintenance savings

  • Scalable deployment

Real-time insights

  • Real-time predictions

  • Adaptive learning

  • Faster model building

Adaptive model efficiency

  • Continuous model improvement

  • Improved efficiency

  • Streamlined production

Looking ahead

Broader equipment coverage

  • Expand anomaly detection to more equipment types

Predictive maintenance growth

  • Integrate predictive maintenance across additional production lines

Ongoing model refinement

  • Continuously refine machine learning models for improved precision

All rights reserved © 2025 Fractal Analytics Inc.

Registered Office:

Level 7, Commerz II, International Business Park, Oberoi Garden City,Off. W. E.Highway, Goregaon (E), Mumbai City, Mumbai, Maharashtra, India, 400063

CIN : U72400MH2000PLC125369

GST Number (Maharashtra) : 27AAACF4502D1Z8

All rights reserved © 2025 Fractal Analytics Inc.

Registered Office:

Level 7, Commerz II, International Business Park, Oberoi Garden City,Off. W. E.Highway, Goregaon (E), Mumbai City, Mumbai, Maharashtra, India, 400063

CIN : U72400MH2000PLC125369

GST Number (Maharashtra) : 27AAACF4502D1Z8

All rights reserved © 2025 Fractal Analytics Inc.

Registered Office:

Level 7, Commerz II, International Business Park, Oberoi Garden City,Off. W. E.Highway, Goregaon (E), Mumbai City, Mumbai, Maharashtra, India, 400063

CIN : U72400MH2000PLC125369

GST Number (Maharashtra) : 27AAACF4502D1Z8