Smart control of air compressors

The Challenge

The client had 8 air compressors critical to the production line. An unexpected failure meant halting production for 6-8 hours while the brand's technician arrived. Maintenance was calendar-based: changes every 500 hours — but some parts lasted 2,000 hours and others failed at 300.

Our Solution

• Proprietary sensors: pressure, vibration, temperature, current, operating hours. Connected to each compressor with non-invasive installation.
• Predictive model: AI trained with failure history + real-time patterns predicts failure probability in the next 72 hours.
• Remote control: start, stop, and load modulation from the dashboard, without having to go down to the machine room.
• Escalated alerts: WhatsApp to the technician on duty, email to the supervisor, SMS to the manager if no one responds within 10 min.

Measurable Results