1. AI-Powered Mobile Inspections (Digital Health Rounds)
- Challenge: Manual equipment inspections were time-consuming, prone to human error, and provided delayed insights, leading to unplanned downtime and safety risks.
- Solution: We developed an AI-powered mobile assistant for field engineers. The solution leverages computer vision to automatically detect defects from photos, voice recognition for hands-free reporting, and an AI agent to provide instant access to technical documentation.
- Outcome: Achieved a 30-40% reduction in inspection time, significantly improved data accuracy, and enabled a proactive approach to maintenance by identifying issues before they escalate.
2. Predictive Maintenance (APM) for a Combined Cycle Power Plant
- Challenge: A major energy provider needed to minimize unplanned downtime for its critical gas turbines, as 89% of failures were not related to equipment age and were unpredictable with traditional methods.
- Solution: We implemented an enterprise-grade AI system based on empirical modeling (Similarity-Based Modeling). The system analyzes thousands of real-time sensor data points to build a "digital twin" of normal operation and predict deviations long before standard alarms are triggered.
- Outcome: The system provides early warnings for potential failures weeks in advance, resulting in a calculated economic benefit of over $600,000 per year for every 500 MW of capacity by preventing catastrophic failures and optimizing maintenance schedules.
3. Autonomous Quality Control in Metallurgy
- Challenge: A metallurgical plant faced challenges with detecting micro-defects in steel rolls, leading to quality inconsistencies and customer complaints.
- Solution: We deployed a custom AI model with a high-resolution computer vision system directly on the production line. This Edge AI solution analyzes the surface of each roll in real-time, identifying defects invisible to the human eye with over 99.5% accuracy.
- Outcome: Reduced defect rate by 15%, decreased customer claims, and provided a valuable data stream for process optimization.