Unplanned Downtime Reduction
Proprietary AI time-series anomaly detection shifts from reactive repair to predictive early warning
DTU / Sensor Compatibility
MQTT, Modbus-RTU/TCP standard protocols — reuse existing equipment
Rapid Onboarding
No production line modification needed — standard protocol devices connected quickly
Per Unit / Year
Printed right here: 1-4 units $420/unit-year, 5-19 units $280, 20+ units $140. Hardware excluded — use what you already have.
Note: The figures above are common industry estimates rather than official statistics. Actual losses and energy savings vary widely by industry, production line, and equipment condition — please rely on on-site assessment.
What Is Your Equipment Telling You?
Equipment doesn't suddenly fail — changes in temperature, vibration, current, and energy consumption are distress signals it sends.
Temperature Anomaly
Detect overheating, cooling failures, and wiring degradation before equipment burns out.
Vibration Anomaly
Catch early signs of bearing wear, imbalance, and looseness — warn before failures escalate.
Current Anomaly
Identify overload, phase loss, and stall conditions. Monitor motor status and load changes in real-time.
Energy Anomaly
Spot hidden waste — leaks, idle equipment, and abnormal off-hour consumption patterns.
Why do equipment failures always seem to happen out of nowhere?
It's not that your O&M team isn't working hard — the tools just haven't kept up. From reactive firefighting to proactive early warning, the missing piece is an AI monitoring system that learns and closes the loop.
Traditional Approach
Fixed Threshold Alerts
Alerts only fire when limits are exceeded — slow degradation goes unnoticed. A single fault floods dozens of false alerts, burying real risks.
Platform Solution
AI Time-Series Anomaly Detection
Learns each device's operational baseline to detect slow drift and hidden anomalies. 80% fewer false alarms, alerts routed to the right people.
Traditional Approach
Phone Calls / Group Chats
Alerts dumped into chat groups — who handles what? Night alerts buried, discovered the next day.
Platform Solution
WeCom/SMS Graded Push + Auto Workflow
Graded, person-specific routing by urgency. Unacknowledged alerts auto-escalate. Full traceability: Alert → Work Order → Resolution → Archive.
Traditional Approach
Costly Retrofits & Downtime
New monitoring systems often require rewiring, equipment replacement, and production stoppage — long project cycles impacting output.
Platform Solution
Reuse Existing Sensors, Plug & Go Live
Compatible with 95% of DTUs/sensors. MQTT/Modbus standard protocols. No production line changes — 30 minutes to complete data integration.
From "Fix After Failure" to "Early Warning Before Failure"
Traditional maintenance relies on manual inspections — anomalies are often only discovered after losses occur. ZHIYUAN makes equipment status visible in real-time, actively warning before failures escalate.
Traditional Maintenance
- 1Equipment Running
- 2Anomaly Occurs
- 3Equipment Stops
- 4Manual Discovery
- 5Emergency Repair
- 6Production Loss
→ Downtime Loss + Emergency Repair + Production Impact
ZHIYUAN Smart Early Warning
- 1Equipment Running
- 2Real-Time Monitoring
- 3Anomaly Detected
- 4Early Warning
- 5Proactive Maintenance
- 6Downtime Reduced
→ Less Unplanned Downtime + Lower Repair Costs + Continuous Production
Full-Stack AIoT capabilities — the invisible guardian of your equipment
Five steps to close the loop: Connect, Store, Detect, Visualize, Resolve. Peace of mind for every operation.
AI Intelligent Alert Engine
Traditional monitoring relies on fixed threshold a…
Click for detailsMulti-Protocol Device Access
Supports MQTT, Modbus-RTU/TCP and other mainstream…
Click for detailsTime-Series Data Storage & Playback
Built on a time-series database for massive device…
Click for detailsVisual Data Dashboard
Real-time overview of all device online status, re…
Click for detailsMobile Work Order Closed-Loop
Alerts generate maintenance work orders with one c…
Click for detailsYour factory is facing these three hidden losses
Data sourced from authoritative industry reports and academic research. ZHIYUAN believes data is the greatest productivity, and safety is the greatest efficiency.
$400-4,000/hour
Direct loss range from unplanned downtime in SMEs — varies widely by industry and production line
Common industry estimate40%
Traditional threshold alarms carry a high false-positive rate, burying real risks
Common industry figure (varies by study)8-15%
Energy leakage accounts for 8-15% of total factory energy consumption — hard to detect manually
Typical range found in energy auditsSeed Customers Wanted: Not a Free Pilot — a Creditable Deposit
We no longer run purely free pilots — unpaid engagements get no resources and prove nothing about willingness to pay. The rule now: diagnosis is free, the pilot takes a deposit, and it is credited to your annual fee.
- First 3 units diagnosed free, with report and downtime-cost maths
- Pilot deposit ¥3,000-5,000, fully credited to your annual fee
- Acceptance metrics (online rate ≥ 95%, false alerts, closure time) in the contract
- Fail acceptance and the deposit is refunded — no annual fee
Reserve a Pilot Slot
Limited slots this round — requires an equipment list and site survey
We Don't Sell Seats — We Sell Less Downtime
No one in an SME factory stares at dashboards all day. So we take the whole job: connect the machines, watch for anomalies, dispatch work orders, send monthly reports. You just get the phone call before it breaks.
Step 1
Free Diagnosis
First 3 units — get an AI health report
$0one-off · first 3 units only
- Pick any 3 air compressors / pumps / fans
- Connected in 30 minutes (reuse existing DTUs & sensors)
- AI health report: baseline comparison, degradation trend, risk ranking
- Downtime-cost maths included: potential annual loss vs annual fee
Step 2
Pilot Onboarding
Refundable deposit, credited to your annual fee
$420-700deposit · credited to annual fee
- Site survey, point configuration, commissioning
- Dedicated dashboard with alert rules tuned to your conditions
- WeCom / SMS graded alerting, alert-to-work-order closed loop
- 60-day pilot, AI baseline trained on your real data
Step 3
Managed Health Service
Priced per unit per year, monthly report included
$140-420per unit / year
- Full anomaly detection and graded alerting
- One file per machine: health record, degradation trend, repair history
- Monthly health report + quarterly review call
- Auto work-order dispatch with escalation on timeout
Step 4
On-Premise Deployment
Data stays in-plant, project-based pricing
$7,000starting / project
- Deployed on the customer's own servers — data never leaves the plant
- Integrates with MES / OA / ERP and existing identity systems
- Custom equipment protocols and reports
- Implementation, training, acceptance docs and O&M handover
Full pricing & volume tiers →Calculate my annual downtime cost →
Predictive Maintenance for Air Compressors, Pumps, Fans & Motors
We are not building a one-size-fits-all IIoT platform. We studied the failure modes of four core rotating equipment types — so SME factories can actually afford predictive maintenance. Non-intrusive monitoring: no equipment replacement, no line modification, 30-minute data integration.
30-Minute Quick Onboarding, 24/7 Online Guardian
Not a one-off project — a long-term partnership. Data-driven from day one, so every operation runs with peace of mind.
30-Minute Quick Onboarding
Standard protocol devices use our point table template. Data reporting and integration completed within 30 minutes. Complex protocols evaluated separately — no over-promising.
7×24 Dedicated Support
Business hours tech support hotline + always-on alert monitoring channel. Real-time emergency response — no issue left overnight.
Data Security Assurance
Encrypted transmission + tiered time-series storage. Data retention based on subscription plan. Key data can be exported periodically by customers.
Every Case Comes Down to Money
No fluff about "improving management". Every case answers three questions: how many hours saved, how much money saved, how fast the payback.
Machinery Manufacturing
Hebei Xinda Machinery Co., Ltd. | Air Compressor/Pump Predictive Maintenance
Hebei XX Machinery Plant | 12 Air Compressors/Pumps Predictive Maintenance
- -62%unplanned downtime
- 12units online
- Bearing degradation trend detected 2 weeks in advance, preventing 3 unplanned shutdowns
Accepted
Elevator Maintenance
Beijing Tongda Elevator Maintenance Co., Ltd. | Elevator Intelligent Monitoring & Digital Maintenance
Beijing XX Elevator Maintenance | 68 Elevators Intelligent Monitoring
- -47%unplanned downtime
- 68units online
- Door anomaly detected 3-7 days in advance, preventing entrapment incidents
Pilot Completed
Manufacturing Plant
Air Compressor & Pump Electromechanical Equipment Status Monitoring (General Solution)
Manufacturing Plant | Air Compressor/Pump Status Monitoring
- -62%unplanned downtime
- 12units online
- Bearing degradation trend detected 2 weeks in advance, preventing 3 unplanned shutdowns
Pilot Completed
Aquaculture Farm
Farm Environmental Temperature & Humidity IoT Monitoring
Aquaculture Farm | Environmental Temperature & Humidity IoT Monitoring
- 24units online
- Temperature fluctuation early warning 30 min in advance, preventing cold stress in an entire shed of chicks
Pilot Completed
Warehouse & Storage
Warehouse & Cold Storage Temperature & Humidity Alert Monitoring
Warehouse & Storage | Temperature & Humidity Alert System
- 36units online
- Doorway short-term temperature spikes intelligently filtered — true refrigeration failures alerted within 5 min
Pilot Completed
Industrial Park
Water, Electricity & Gas Energy IoT Auto Meter Reading & Anomaly Detection
Industrial Park | Water, Electricity & Gas Energy IoT Monitoring
- 52units online
Pilot Completed
Basis: comparisons are between pre- and post-pilot periods of equal length, not third-party audited, and do not constitute a performance guarantee. Actual results vary with operating conditions, equipment age and maintenance practice — acceptance data governs.
Download Free Industry Solution Whitepapers
Includes industrial equipment early warning, energy management, and smart aquaculture scenarios, with industry data and ROI estimation models.
Motor Current Anomaly? Don't Rush to Replace Equipment — It May Be Early Bearing Wear
Slowly increasing motor current is often more dangerous than sudden overload. This article breaks down how current trend analysis helps factories catch bearing degradation signals before failure, avoiding unplanned downtime.
Why Traditional Threshold Alerts Are Dragging Down Your O&M Team
Over 40% of threshold alerts are invalid. Alert storms, alert fatigue, and real risks buried in noise — this article uses data and scenario comparisons to explain why factories need AI alert noise reduction.
Energy Leakage Accounts for 8–15% of Factory Energy Consumption — Here's How to Pinpoint It
Water, electricity, and gas leaks won't show up on monthly bills — they appear in off-hours sub-meter data. This article explains how sub-metering + time-segment comparison can precisely locate energy anomalies.
4 Resources to Help You Decide
All free — just fill in your name, phone, equipment type, and device count to access.
Downtime Loss Calculator
Online calculator + downloadable Excel template — input device count, unit value, and average downtime to auto-calculate annual potential losses.
Calculate & Download Excel →Vibration Self-Check Handbook
PDF handbook with illustrated common vibration anomaly types, diagnostic criteria, and solutions. View online or print as PDF.
View & Download PDF →Free AI Health Diagnosis
First 3 devices free — 30-min data onboarding with AI health assessment report.
Check 3 Devices Free →ROI Calculator
Online calculator: estimate annual maintenance cost savings and downtime loss reduction after deploying monitoring.
Calculate ROI →Answers to Your Equipment Monitoring Questions
Can legacy equipment be connected?
Yes. The platform supports standard industrial protocols like MQTT/Modbus and is compatible with mainstream DTUs and sensors. No equipment retrofit needed.
What sensors need to be installed?
Depends on your monitoring needs — temperature, vibration, current, humidity, etc. Hardware is procured by the customer or reused from existing equipment; we handle the integration.
Can it be deployed on-premises?
Yes. We support private deployment, with all data remaining on your premises for security and compliance.
What happens after an alert?
Alerts are routed by severity to WeCom/SMS. A work order is auto-generated. Unacknowledged alerts auto-escalate. Full process is logged.
How long does a project take?
Standard protocol devices integrate in 30 minutes. Projects including hardware installation typically go live within 1-2 weeks.
Do the maths before you decide
Enter your unit count, cost per downtime event and annual events — you get your potential annual loss, our annual fee, and the gap. After the free diagnosis we stop contacting you unless you reach out first.
Risk reversal: first 3 units free; pilot deposit credited in full after acceptance, refunded if not.