How Vale avoided $7.8M in losses through predictive maintenance on rotating equipment
Always-on vibration and process analytics flag emerging faults. Early fixes prevent breakdowns and production loss.
Context
The operation experienced repeated unplanned downtime due to faults that were not detected early enough. Manual inspections and standard monitoring tools often failed to catch issues before they escalated. These failures disrupted production and increased maintenance costs.
Solution
The site implemented online condition monitoring combined with predictive analytics to continuously analyze equipment behavior. The system used sensor data to identify anomalies and provided early alerts to operators. This proactive approach allowed teams to address issues before failures occurred.
Results
The solution helped avoid $7.8M in production loss, as documented in the case study. Earlier warnings reduced severe failures and contributed to more stable and predictable equipment performance.
Data Inputs
Vibration, temperature, process load