Solutions · Predictive Maintenance
Stop reacting. Start predicting.
Combine the Digital Twin's alarm engine, telemetry trending, and MTBF/MTTR tracking to shift from calendar-based maintenance to condition-based — and eventually predictive — maintenance.
Maintenance Maturity
Where are you today?
Most manufacturers are stuck between reactive and preventive. DFI gets you to condition-based in weeks and predictive within months.
Reactive
Fix it when it breaks. No data collection.
Preventive
Calendar-based schedules. Over-maintain or under-maintain.
Condition-Based
Monitor live telemetry. Act on actual asset health signals.
DFI starts here
Predictive
Trend analysis + alarm correlation predicts failure windows.
Capabilities
Four building blocks of predictive maintenance
Configurable Alarm Engine
Set thresholds per asset, per parameter — with dead-band, delay, and severity levels. Escalation rules route critical alarms to the right technician via SMS, email, or webhook. Bulk acknowledge and annotate from the alarm console.
- Dead-band and time-delay to eliminate nuisance alarms
- Severity tiers: Info, Warning, Critical, Emergency
- Escalation chains with configurable timeout
- Alarm shelving for planned maintenance windows
Telemetry Trending & Anomaly Detection
Overlay any parameter against time, shift, or production batch. Built-in statistical process control detects drift before it crosses alarm thresholds. Annotate trends with maintenance events to correlate cause and effect.
- Multi-parameter overlay on a single time axis
- Moving average, standard deviation, and Cpk auto-calculation
- Annotations linked to maintenance work orders
- 90-day hot storage, 2-year warm tier, unlimited cold archive
MTBF / MTTR Tracking
Automatically calculate Mean Time Between Failures and Mean Time To Repair per asset, per failure mode. Identify your worst-performing assets and most time-consuming repair categories to prioritize maintenance investment.
- Auto-calculated from alarm-to-resolution timestamps
- Breakdown by asset, failure mode, shift, and technician
- Pareto of top downtime contributors
- Target setting with red/amber/green status indicators
Automated Work Order Triggers
When a condition threshold is crossed, DFI can auto-generate a maintenance work order in your CMMS/EAM system — or in the built-in work order module. Include asset context, recent telemetry, and suggested parts.
- Trigger on alarm, on threshold, or on MTBF degradation
- Pre-populated work orders with asset context and recent readings
- Integration with SAP PM, Maximo, UpKeep, and Fiix via API
- Built-in lightweight work order tracker for teams without a CMMS
Results
Before and after DFI
Aggregate results from three manufacturing sites after 6 months of condition-based maintenance with DFI.
| Metric | Before | After DFI | Improvement |
|---|---|---|---|
| Unplanned downtime | 12.4 hrs/month | 4.1 hrs/month | 67% reduction |
| Maintenance cost per asset | $2,840/yr | $1,920/yr | 32% reduction |
| Alarm noise (false positives) | 340/week | 45/week | 87% reduction |
| MTTR (avg) | 4.2 hrs | 1.8 hrs | 57% faster |
Connects to your existing stack
DFI ingests telemetry from any protocol and pushes work orders to your CMMS.
How It Works
From sensor to work order in four steps
Ingest telemetry
DFI Edge Gateway connects to PLCs, sensors, and SCADA via OPC UA, MQTT, or Modbus. Data flows to the twin engine in sub-second intervals.
Evaluate thresholds
The alarm engine evaluates every reading against configurable thresholds with dead-band and delay. Only real anomalies trigger alerts.
Trend and correlate
Trending overlays show parameter drift over time. Statistical rules detect patterns before they breach alarm limits.
Trigger action
When conditions warrant intervention, DFI auto-generates a work order with asset context, recent telemetry, and suggested spare parts — sent to your CMMS or managed in the built-in tracker.
Cut unplanned downtime by 60% or more
Start with your highest-downtime line. We'll show measurable results in a 6-week pilot.