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Machines kept stopping after shift change and repairs missed the root cause.
A consumer products plant needed failure risk to surface before abrupt stoppages broke customer commitments.
Client
Consumer Products Manufacturing Plant
Duration
6 months
Industry
Manufacturing
−10%Unexpected Breakdowns
25% YoYTrend Reversed
LiveMachine Risk Scores
24/7Monitoring
Client problem
In their words
Unscheduled maintenance had grown 25% year-over-year. Machines were stopping abruptly, repairs weren't solving root causes, and the plant was missing customer commitments as a result.
What ZapSight built
One operating system around the failure mode
- Integrated directly with machine PLC and SCADA systems
- Captured vibration, temperature and process metrics before and after every failure
- Logged operator and process context for each breakdown event
- Trained AI models to predict failures across machine classes
- Recommended root causes at failure time and recorded mechanic actions taken
Technologies Used
SCADAPLCPyTorchInfluxDBGrafana
"We can now tell customers when a machine is at risk before it fails — not apologize after.