Operational Challenges
- Frequent unplanned CNC machine breakdowns
- Limited visibility into machine health conditions
- Reactive maintenance approach
- Inconsistent OEE across machines and shifts
- Production delays due to sudden failures
Client Profile
Modern Coach Factory (MCF), Raebareli, a production unit of Indian Railways, manufactures advanced railway coaches with strict quality and precision standards. The facility operates multiple CNC machining centers critical to coach fabrication.
Machine Downtime Analysis Graph
Solution Implemented
A real-time predictive maintenance platform was deployed to monitor CNC machine health, detect anomalies early, and provide actionable insights for maintenance teams.
Real-Time Monitoring
Continuous monitoring of spindle vibration, temperature, load, power consumption, and cycle times.
AI-Based Analytics
Machine learning models identify abnormal patterns and predict potential failures before breakdown occurs.
Smart Alerts
Threshold and trend-based alerts sent to maintenance teams for early intervention.
Predictive Maintenance Dashboard Screenshot
Visualization & Dashboards
- Live machine status (Running / Idle / Breakdown)
- OEE dashboards (Availability, Performance, Quality)
- Machine health score and failure probability
- Shift-wise and machine-wise performance comparison
Measurable Outcomes
38%
Reduction in Unplanned Downtime
22%
Improvement in OEE
5.5 Months
Return on Investment
Conclusion
The predictive maintenance initiative at MCF Raebareli enabled a transition from reactive maintenance to a proactive, data-driven strategy. The solution improved machine availability, reduced maintenance costs, and enhanced overall production efficiency.