Machinery Manufacturing
Hebei Xinda Machinery Co., Ltd. | Air Compressor/Pump Predictive Maintenance
Hebei XX Machinery Plant | 12 Air Compressors/Pumps Predictive Maintenance
Pain Points
12 critical power equipment units (8 air compressors, 3 pumps, 1 fan) rely on manual inspection, averaging 2.3 unplanned shutdowns per month with ~¥4,000 loss per incident. No equipment operating baseline data; "run-to-failure" maintenance mode with high spare parts inventory costs.
Implementation Plan
Monitoring Targets
Vibration, temperature, current, runtime, and start/stop frequency of air compressors, pumps, and fans
Pilot Scope
First batch: 12 critical equipment units covering all production line power equipment
Tech Stack
Pilot Acceptance Criteria
- Device online rate ≥ 95% (daily heartbeat statistics)
- Normal operating baseline established per device (7 consecutive days of normal data modeling)
- Degradation trend alerts traceable to specific time windows
- Alert-to-work-order closed-loop duration measurable
Results
12 unitsConnected Devices
↓ 62%Downtime Reduced
↓ 80%Inspection Reduced
Bearing degradation trend detected 2 weeks in advance, preventing 3 unplanned shutdownsAdvance Warning
From 2-hour human discovery → AI 4-hour early warningResponse Time
Air compressor load rate optimized, saving 11.5% on electricityEnergy Saved
Key Highlights
- Customer: Hebei Xinda Machinery Co., Ltd. (100-500 employees, metal parts manufacturing)
- Deployment: March 2026, 7-day deployment cycle
- Deployment cost: ¥18,600 (sensors, gateway, installation & debugging)
- Monthly unplanned downtime reduced from 2.3 to 0.5 incidents (= pre-pilot 90 days vs post-pilot 90 days)
- Downtime reduction 62% = pre-pilot 90-day unplanned downtime vs post-pilot 90-day unplanned downtime
- Inspection personnel reduced from 4 to 1 person/day, annual labor cost savings ~¥36,000
- Maintenance shifted from reactive repair to planned maintenance — spare parts inventory cost down 30%
- Annual estimated savings: ~¥87,000 (downtime loss reduction + energy savings + labor savings)
- ROI: ~2.5 months payback
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