Manufacturing & Heavy Industry
Predictive maintenance software for manufacturing & heavy industry
Sensor Intelligence ingests process telemetry from PLCs, SCADA, and historians, and surfaces the drift signatures that precede unplanned downtime.
Built for manufacturing and heavy-industry operators who would rather see a failure six weeks before it happens than write up a postmortem.
Signals you already have
PLC and SCADA tags, OPC UA streams, vibration and acoustic sensors, energy consumption per line.
Decisions you're missing
Which line will go down this shift. Which machine's bearing pattern matches a failure history. Which energy spike is a sensor lie, not a real event.
What Explore changes
Predictive maintenance grounded in cross-signal physics, not single-channel thresholds. Causal filtering kills the alarm storm. A queue ranked by production impact.
Where it lands
Manufacturing & Heavy Industry — the operational picture.
Industrial telemetry is rich but operationally opaque. Statistical thresholds miss the slow drifts. Vendor-specific tools don't talk to each other. The team most affected by unplanned downtime is the team least likely to have time to write a custom analytics layer.
Ingest from OPC UA, Modbus, and PLC-vendor APIs. Cross-signal physics constraints catch the failure modes single-channel thresholds can't see. The output is a queue of pre-failure tickets — not a wall of metrics — so the operations team can plan maintenance around the line, not around it. On the energy side, the same feed powers industrial energy management software that ranks the waste by cost. For a deeper walkthrough of predictive maintenance techniques and failure-mode detection, see our predictive maintenance guide for manufacturing.
Built for
Operations, reliability, and maintenance leadership at process manufacturers, discrete manufacturers, and heavy-industry operators.
What changes
- Pre-failure detection commonly 4–8 weeks ahead of conventional vibration thresholds.
- Alarm storms collapsed into single root-cause tickets.
- Predictive maintenance grounded in cross-signal physics, not single-channel rules.
- Operations-team time freed from manual triage of legacy SCADA noise.
Worked example
One real shape of the problem.
A pulp mill operator: a single bad pressure sensor had been the root cause of an alarm storm flagged daily for a year. Cross-signal incoherence detection caught it in 11 days. The team saved 6 hours/week previously spent triaging cascading alarms.
Regulatory & compliance notes
What auditors expect, where we sit.
OPC UA, Modbus, and PLC-vendor protocols. Write access starts off.
Quick facts
- EU data residency by default.
- Ingest from existing systems.
- No PII processed by Sensor Intelligence.
- Customer-hosted or managed SaaS.
What's your building not telling you?
Tell us what you're trying to figure out: energy drift, a BMS you don't trust, compliance you're chasing. We listen first, then tell you straight whether Explore helps. 30 or 60 minutes, your pick. No commitment either way.