# Predictive maintenance and ops dashboards for a UK industrial manufacturer

> UK industrial manufacturer (£800m turnover) · Industrial & Aviation

A heavy industrial manufacturer was losing £4m a year to unplanned downtime. We deployed predictive maintenance models on their existing sensor data and built operations dashboards their plant managers actually use.

## At a glance

- **65%** Less downtime
- Engagement: 16 weeks
- Team: 5 engineers

## What was the problem?

The manufacturer operated four production sites in the UK and had a long-standing problem with unplanned equipment downtime. The annual cost was approximately £4m in lost production. They had already installed sensor packages on the critical machinery as part of an earlier digitalisation programme but the data was sitting unused in a data lake.

## What did QuantSpark do?

We started with a two-week diagnostic phase to identify which machinery was driving the downtime and what failure patterns were detectable from the existing sensor data. The answer was that roughly 70 percent of the unplanned downtime was concentrated in 12 pieces of equipment and the failure patterns were detectable up to 14 days in advance from the existing sensor streams.

We built failure prediction models for each of those 12 machines, integrated with the existing CMMS so that the plant maintenance teams received tickets in their normal workflow. We also built an operations dashboard for the plant managers that surfaced equipment health, throughput, and predicted issues in a single view.

## What changed?

Unplanned downtime fell by approximately 65 percent on the equipment covered by the predictive models in the twelve months following deployment. The business case projected £2.5m annual savings against actual measured savings of £2.8m. The plant managers report using the operations dashboard daily, which is unusual for an analytics deployment of this kind.

> "I have been pitched predictive maintenance by every vendor in the market for ten years. This is the first one that actually changed how we run the plants."
>
> Group Operations Director, UK industrial manufacturer

---

Canonical page: https://quantspark.ai/case-studies/industrial-predictive-maintenance
More about QuantSpark: https://quantspark.ai/llms.txt