Context
Vacuum pumps are at the heart of many industrial processes. Any failure can lead to costly production downtime and operational risks.
Traditionally, maintenance has been carried out reactively — only after a fault occurs — resulting in repeated shutdowns and rising costs.
To address these constraints, the operator was looking for a solution capable of aligning maintenance schedules with the actual condition of the equipment, in order to balance availability, safety and cost control.
Using historical data from the pumps (pressure, temperature, vibration, etc.), DiagFit automatically generated end-of-life prediction models.
Early warning signs were detected between two months and seven days before failure (≈50% probability at D-60, 88% at D-30, 100% at D-7).
Challenge
How can pump availability be maximised while reducing maintenance costs?
The client needed a solution able to:
- Anticipate failures to reduce maintenance expenses (fewer emergencies, fewer unplanned shutdowns);
- Plan maintenance operations in advance, allowing several days to order parts, allocate teams, and schedule interventions efficiently.
Solution
The integration of DiagFit was carried out in several stages:
- Data analysis – collection, cleaning and processing of signals (pressure, temperature, vibration, etc.);
- AI-based modelling – automatic generation of models assessing pump health without requiring deep domain expertise;
- Early anomaly detection – identification of the first deviations from normal behaviour, well before they become visible through traditional methods;
- Optimal intervention timing – precise estimation of when to replace components, to minimise production downtime.
Results
Implementing DiagFit made it possible to:
- Detect 11 out of 15 failures before breakdown, with a lead time ranging from 2 months to 7 days;
- Achieve over 40% savings in maintenance costs, factoring in intervention and downtime costs before and after DiagFit deployment.
- Beyond the financial gains, the client reported greater satisfaction with the equipment supplier’s service and smoother production with minimal interruptions.
This use case illustrates how DiagFit transforms vacuum pump maintenance: fewer failures, fewer stoppages, lower costs — without adding operational complexity.
