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Case Study: MTBF 18h → 165h

A quick narrative of the project that combined data collection, analytics and TPM to cut unplanned downtime.

Initial challenge

An extrusion line stalled every 18 hours due to cylinder failures and overheating. SCADA alarms were isolated and there was no live visibility for maintenance.

What we deployed

  • Connected Siemens PLC and Modbus sensors through an MQTT gateway.
  • Python + Grafana models to forecast anomalies and trigger alerts.
  • Focused TPM routines addressing root causes and setup variation.

Impact

  • MTBF jumped from 18 to 165 hours within 10 weeks.
  • +11% availability and 7% scrap reduction.
  • Live dashboard for maintenance and operations teams.
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