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Predictive Maintenance System Development (PdM) & Modernization

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  • CAPTURE OPERATIONAL TRUTH

    Model equipment while it operates under real load, uncovering hidden logic, operator workarounds, and drift to reduce MTTR.

  • ACT INSIDE YOUR WORKFLOW

    Feed predictions into SCADA, MES, ERP, and CMMS to automatically generate tickets, prioritize interventions, and align schedules.

  • SCALE WITHOUT DEPENDENCIES

    Connect legacy machines with modern sensors, standardize interfaces, and keep everything upgrade-friendly.

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Why It Matters

The only PdM that pays off is the one that works inside your actual operations.

Predictive maintenance (PdM) only works when it reflects how equipment behaves in real operations, and is grounded in data-centric engineering with the level of observability needed to form true context-aware intelligence on the line.

The biggest gains appear when predictive maintenance systems connect directly to SCADA, MES, ERP, and CMMS and operate as event-driven, fault-tolerant adaptive stacks that trigger actions inside existing workflows. Plants that run predictive maintenance as part of daily operations report 30-50% fewer unplanned outages, up to 40% lower MTTR, and a payback period of 6 to 24 months.

We make predictive maintenance system development practical and scalable.

Our engineering-first approach integrates with any setup, rolls out across lines quickly and runs as a clean-coded, computational-minimalist runtime that gives technicians the signals they need — without adding another dashboard to manage. Each deployment comes with enterprise-grade SLAs, certified integrations and security you can trust to run at production scale from day one. PdM only becomes a long term advantage when it reflects operational truth, executes inside your workflows, grows with your network through computational symbiosis between equipment and analytics and meets enterprise expectations for resilience, security and scale.

Modernizing unstable systems? Launching new products?

We build development environments that deliver enterprise-grade scalability, compliance-driven security, and control baked in from day one.

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Our Edge

Why choose Devox Software?

  • Modernize
  • Build
  • Innovate

Legacy systems slowing every predictive initiative?

We revive your equipment with clean data, stable integrations, and retrofit-ready precision.

Hard to scale PdM to new lines or sites?

We standardize data, models, and integrations so PdM rolls out cleanly across equipment, shifts, and plants.

PdM models failing because of noisy or incomplete data?

We clean, align, and validate every signal to ensure your models receive the consistent input they need for reliable failure prediction.

PdM still stuck at the concept level?

We turn your use case into a production-grade system with validated models, real data flows, and clear operational logic.

Data pipelines failing to support predictive workloads?

We engineer robust ingestion, streaming, and storage layers built for uptime, scale, and signal consistency.

Early predictions lack stability under real equipment conditions?

We refine models with domain-aligned features, sensor context, and continuous feedback from your operations.

Predictive performance hitting a ceiling?

We elevate accuracy with advanced ML architectures, sensor fusion, and domain-specific feature pipelines.

Static models falling behind changing equipment behavior?

We build adaptive systems with drift tracking, automated retraining, and real-time recalibration.

Looking to go beyond traditional failure prediction?

We create digital twins, root-cause intelligence, and AI copilots that compress diagnostics into seconds.

What We Offer

Services We Provide

  • AI/ML-Based Predictive Analytics

    Identify potential failures before they occur — powered by AI predictive maintenance solutions and precision models built through algorithmic imagination and tuned for your exact equipment.

    Even in the most rapidly expanding industries, delays are too expensive. To stay ahead, your models need to do more than just predict failures: they need to break down what went wrong, be able to handle unusual situations, and keep learning from real-world data.

    That’s why our predictive analytics services go way beyond just pretty charts and dashboards — we deliver insights that you can actually act on:

    • Accurate failure prediction models. We build models that take into account the real-life behavior of your equipment — not just hypothetical scenarios.
    • Signal engineering. We convert high-frequency, noisy sensor data into structured, machine-specific signals that reveal the true behavior of your equipment.
    • Model retraining pipelines. We set up pipelines that keep our models learning and improving based on what we’re actually seeing in real-world maintenance — all through automated workflows.
    • Root cause attribution. We combine model monitoring — things like when the model starts to decay or when the data changes — with explainability tools like SHAP, LIME, and counterfactual analysis to really get to the bottom of things.
    • Context-aware inference. We put signatures into context, so our models aren’t just spitting out false positives — they’re grounded in the real-world logic of your operation.

    As PdM adoption grows (20%+ CAGR), the system provides a foundation that scales with operations without requiring equivalent growth in data or engineering teams.

  • Industrial IoT Sensor Integration

    We transform physical assets into intelligent, data-generating systems.

    We connect and standardize machine data through integrated IoT predictive maintenance integration and apply ML models that interpret real behavior, enabling automation that updates schedules, routes, and rules automatically.

    What we deliver:

    • Full-cycle sensor instrumentation. We select and deploy the right mix of vibration, acoustic, temperature, current, and strain sensors for your assets.
    • Signal processing at the edge. We build real-time acquisition pipelines with denoising, filtering, timestamp alignment, and contextual tagging, using Kafka, Apache NiFi, and InfluxDB.
    • Multi-sensor synchronization. We synchronize data from multiple sensors to provide a complete, real-time picture of equipment behavior.
    • IoT gateway configuration. We configure secure, fail-safe IoT gateways, built to withstand harsh industrial environments with integrated OT/IT systems.
    • Scalable storage for high-frequency data. We design time-series storage that supports both high-resolution analytics and long-term trend extraction.

    Since machine data is standardized, contextualized, and fed into ML models, the system can automatically adjust production schedules, routes, and rules — lowering operator workload and reducing human error.

  • Legacy Equipment Modernization

    Our predictive maintenance modernization services retrofit legacy assets with intelligence, transforming antiquated technology into an adaptive stack that unlocks predictive capabilities without replacing what already works.

    According to Precedence Research, the PdM segment linked to legacy equipment will explode from $9B in 2025 to nearly $80B by 2034. The reason? Most of the world’s machinery isn’t cloud-native — it’s decades old, undocumented, and irreplaceable. This is where our expertise makes the difference. We’ve modernized PdM environments built on analog systems, outdated PLCs, and proprietary field buses.

    What we deliver:

    • Sensor compatibility. We craft custom sensor mounts & non-invasive integration methods that let you monitor in real-time — even on machines which were never designed to be smart. And we make sure you get accurate signals without disrupting the work flow.
    • Protocol bridging. We connect the old fieldbus & control protocols with newer internet-of-things stacks by using edge gateways & real-time data translators — and we do it in a way that makes sense for your business.
    • Digital twin reconstruction. We reconstruct the real operating logic of your legacy machines, even when documentation is missing.
    • Lifecycle analytics. We overlay PdM models onto the normal wear & tear pattern of your older machines, taking into account how they’ve been run hard & put away wet over the years.
    • Maintainability strategy. We make sure that — no matter what happens — your machines will be easy to keep running long into the future. We provide all the schematics, diagrams & upgrade plans you need to keep them going.

    Instead of foisting expensive new equipment on you, our service brings some real brains to machines that last. We’re talking decades old here — still running strong, but not exactly cutting edge. Our way means you get the most out of your assets without breaking the bank.

  • Scalable Architecture & Multi-Site Deployment

    We engineer industrial AI predictive maintenance development architectures that expand cleanly, leveraging algorithmic design focused on delivering reliable, technician-ready outputs at scale.

    Industrial operations evolve fast: different PLC generations, mixed sensor densities, hybrid OT/IT stacks, and continuous workflow adjustments. This dynamic environment drives the adoption of cloud-based MES and PdM platforms, rising from $2B in 2025 to $4.7B by 2035, fueled by the need for shared data foundations, consistent analytics, and reliable multi-site governance.

    We design predictive maintenance system development topologies that handle enterprise-level sensor loads, cross-plant synchronization, compliance, and GenAI-driven intelligence — enabling PdM to deliver stable performance at both pilot and network scale.

    What we deliver:

    • Unified multi-site data layer. A shared data architecture that consolidates sensor, PLC, SCADA, MES, and ERP signals into one coherent operational model across all plants.
    • Hybrid cloud and edge execution. Real-time inference at the edge, high-density analytics in the cloud. Each layer carries a clear role: responsiveness on-site, computational depth in the core.
    • Horizontal scaling for sensor pipelines. We design pipelines that can handle increasing sensor data as you add new lines or sites, keeping performance stable as your operations grow.
    • Template-based deployment kits. A repeatable rollout package for every new site: asset adapters, mapping schemas, ML bundles, alert templates, and integration presets, enabling rapid, predictable expansion.
    • Cross-stack interoperability. A vendor-neutral integration layer that aligns SCADA, MES, ERP, and CMMS workflows, ensuring consistent automation and shared operational logic across facilities.
    • ML-ready infrastructure. Vectorized knowledge stores, multimodal retrieval pipelines, and asset-aware context delivery to support operator copilots and cross-plant diagnostic intelligence.

    We build predictive maintenance modernization using AI and IoT foundations that grow with the enterprise, enabling each new site, line, or asset class to join the ecosystem with clarity, speed, and architectural stability.

  • Integration with SCADA, ERP, MES, CMMS

    We embed predictive maintenance software system intelligence into your operational stack, where decisions actually happen — advancing human-machine coexistence.

    When The Business Research Company reports a leap from $9.3B in 2024 to $11.82B in 2025, and it’s not about adding more dashboards — it’s about integration. The value of predictive maintenance and condition monitoring systems emerges not in isolation, but when insights flow into your workflow: from shop-floor SCADA signals to ERP-driven asset decisions. We’ve helped manufacturers make PdM part of their real-time fabric — where a failure prediction becomes a ticket, a maintenance task, or a production adjustment.

    What we deliver:

    • SCADA connectivity & data mapping. We make it simple to tap into your SCADA systems (Siemens WinCC, GE iFIX, Wonderware and the like) via OPC UA/DA, MQTT or even custom interfaces if needed, and then link up their tags to equipment hierarchies and set control variables to our prediction models.
    • ERP and CMMs workflow integration. We seamlessly embed PdM outputs into systems like SAP, Oracle EAM, or IBM Maximo for example, and this way automatically kick off work orders, maintenance requests, or procurement actions when our models tell us something important and when it makes sense to act.
    • MES process synchronization. We make sure that our predictions get matched up with the real-world goings on in the shop floor — batch runs, machine states, downtime codes and the like. This is all thanks to our specialized connectors like Ignition, or Tulip, which send context-rich alerts that line up with how your teams actually work day to day.
    • Event-driven architecture. We build flexible pub/sub or webhook-based integration layers that ensure PdM outputs trigger system-level actions in a timely manner, with minimal delay between getting the early warning sign and being able to do something about it.
    • Unified data layer for analytics. We take the telemetry data, your ERP data and feedback from your CMMS and put it all into a single analytics pipeline, so you can look at your whole operation as a whole — see what’s happening with your assets, see how maintenance is affecting operations and get a clearer view on outcomes.

    We use MES events like batch runs, machine states & downtime codes to make sure the alerts teams get are relevant, in context and actually worth paying attention to.

  • Real-Time Monitoring

    We transform your equipment into a continuous stream of operational truth through condition monitoring predictive maintenance, delivering 24/7 visibility.

    The PdM market is projected to expand by $33.7B between 2025 and 2029, driven by one force: real-time awareness. We build machine learning for predictive maintenance layers engineered for sub-second reactions, uninterrupted telemetry, and precision alert routing, so the right team receives the right signal at the right moment.

    What we deliver:

    • 24/7 live equipment health dashboards. Continuous visibility into sensor metrics, degradation patterns, anomaly scores, and operational thresholds, delivered through Grafana, Power BI, or custom interfaces backed by a live time-series infrastructure.
    • Streaming analytics pipelines. Low-latency telemetry processing using Kafka, Spark Streaming, and Flink to evaluate signals in motion, validate patterns, and generate event tags the moment deviation appears.
    • Instant, context-aware alerting. As part of our smart predictive maintenance architecture, alert engines are tuned to model confidence, asset criticality, and failure progression profiles, enabling rapid intervention with minimal noise and clear signal hierarchy.
    • Multi-channel distribution. Alerts are delivered across SMS, mobile, SCADA HMI, Slack, Teams, email, and operator terminals, ensuring every pathway reaches the team responsible for action.
    • Automated escalation flows. Structured response paths aligned with severity, shift schedules, and time-to-intervention requirements.

    With sub-second visibility and validated alerts powered by predictive maintenance artificial intelligence and predictive maintenance internet of things technologies, teams detect overloads, overheating, misalignment, or abnormal vibration long before they become safety hazards or production stoppages. This real-time architecture highlights the tangible benefit of predictive maintenance, detecting failures before they escalate and protecting uptime across every shift.

  • Explainable AI & Trust Layer

    We make artificial intelligence in predictive maintenance decisions context-aware, so your teams will act with confidence.

    We build AI for predictive maintenance models that show both what will happen and why, giving teams clear, auditable logic they can trust and act on. As PdM becomes part of critical operations, explainability becomes essential for safety.

    What we deliver:

    • Model explainability infrastructure. We embed SHAP, LIME, and Integrated Gradients into the ML stack, surfacing feature attribution, decision boundaries, and counterfactuals at prediction time.
    • Human-centric model reporting. We integrate AI in maintenance capabilities to design operator-facing UIs that break down predictions in terms of sensor behaviors, operating conditions, and time-to-failure windows, without requiring ML literacy.
    • Audit-ready decision logging. Every prediction, feature input, and model version is logged for traceability. We enable post-incident analysis and compliance auditing with minimal overhead via AI in predictive maintenance.
    • Trust scoring & threshold calibration. We implement trust scores and confidence bands based on historical accuracy, data coverage, and model drift, helping you decide when to act and when to escalate.
    • Bias & risk analysis for ML models. We run fairness, sensitivity, and robustness checks on your PdM models to detect edge-case failure.

    Predictive maintenance analytics only works if operators believe the signals. Explainability shows why a failure is predicted, turning ML outputs into decisions that engineers feel confident executing.

  • Cybersecurity & Compliance

    We secure every data stream, sustaining your production and reinforcing your predictive maintenance programs, even as your factory becomes more technologically sentience.

    Meta Tech Insights projects PdM cybersecurity investments rising from ~$12B in 2024 to over $100B by 2035. In predictive maintenance, cybersecurity ensures continuous production, uninterrupted data integrity, and full regulatory alignment. Our teams deliver both OT and IT security, creating stable, audit-ready environments across your industrial footprint.

    What we deliver:

    • OT/IT security architecture for PdM. We design and implement a security architecture for your manufacturing network from end-to-end, protecting that critical equipment while keeping the data flowing smoothly and reliably for real-time analysis.
    • Industrial protocol hardening. We enhance Modbus, OPC-UA, MQTT, and legacy fieldbus interfaces with real-time network anomaly detection.
    • Continuous vulnerability management. Our automation covers scanning for all devices and catches configuration drift, unauthorized attempts, and firmware changes instantly.
    • Regulatory compliance automation. We align PdM stacks with ISO/IEC 27001, NIST, GDPR, and industry-specific frameworks, creating audit trails and process documentation at every touchpoint.
    • Incident response integration. We deliver ready-made playbooks and escalation paths that unify IT security and plant operations.

    We turn security into a foundation to optimize maintenance, ensuring every new data source adds measurable strength to your business legacy.

  • PdM Support Services

    We provide custom predictive maintenance development services to keep your PdM system stable, accurate, and aligned with real factory conditions.  Our team monitors model performance before it affects operations, and adapts the system as equipment, processes, or production demands evolve.

    What we deliver:

    • POC design & validation. We build minimal, production-ready prototypes to prove business value with documented test cases, integration blueprints, and cost-performance projections.
    • Full-scale deployment management. We architect and coordinate multi-phase rollouts and change management in parallel, with zero disruption to production flow.
    • Knowledge transfer. We train engineering, maintenance, and operational teams on new PdM workflows with role-based materials.
    • Proactive support & monitoring. We deliver continuous monitoring, issue detection, and root cause analysis through managed or co-sourced service models.
    • Continuous improvement roadmaps. We analyze feedback and performance data, iterate on predictive models, and adapt system logic for new assets.

    We deliver more than go-live: we embed resilience and advanced predictive maintenance techniques into your operations, equipping your teams for every phase, from first pilot to enterprise-wide adoption.

  • ROI Estimation & Business Case Modeling

    We translate predictive maintenance advantages and disadvantages into clear business outcomes, giving your leadership the clarity to invest with confidence.

    Analysts forecast the predictive maintenance in manufacturing business case segment between $5.8B and $15.6B in 2025, yet budget competition intensifies as adoption accelerates. Probably, you face the same decision: which projects justify the investment? Our role — quantify true value through examples of predictive maintenance, eliminate uncertainty, and build models that secure buy-in at every level.

    What we deliver:

    • Payback period modeling. We develop projections for maintenance savings, downtime reductions, asset lifetime extension, and yield improvements, tailored for your operational scenarios.
    • Scenario analysis. We stress-test every variable: failure rates, sensor costs, false positive rates, labor impacts, and energy savings. Our models highlight both best-case gains and real-world limitations.
    • Cost-benefit benchmarking. We help leading predictive maintenance companies compare PdM scenarios to alternative strategies (reactive, preventive, calendar-based) using industry benchmarks and your internal data, clarifying the true delta for leadership.
    • Depreciation impact. We map how PdM shifts asset lifecycles, influencing capex, opex, and balance-sheet planning over multi-year horizons.
    • Stakeholder-ready documentation. We deliver executive-level presentations, data visualizations, and model exports, arming you for board approval, budget cycles, and strategic planning.

    We equip your leadership to see beyond technical promise, proving, in concrete terms, how maintenance prediction compounds value across every line item.

Our Process

Our Predictive Maintenance Enablement Framework

We approach implementation of AI predictive maintenance not as a standard project, but as a transformation of your entire maintenance capability. Every step in our process is tuned for reliability, transparency, and buy-in from your team.

01.

01. Technical Due Diligence

As a predictive maintenance software development company, we always begin with a technical examination of your equipment, data flows, PLC and SCADA behavior, and day-to-day operational practices. This reveals the real logic driving your production environment and uncovers any gaps or dependencies that could impact predictive performance.

02.

02. Infrastructure Readiness

Next up, we make sure your data pipeline is in good nick from end to end. We check the quality of your sensors, whether the timestamps are all in order, how your edge processing is working, and the reliability of your network. If we spot any issues, we fix them so the predictive layer has clean inputs to work with.

03.

03. Live Equipment Validation

We deploy a focused zero downtime predictive maintenance system pilot directly on your production equipment under real load. This confirms how the models behave amid noise, shift changes, SCADA/MES event timing, and operational variability. The pilot verifies that the system works reliably in actual factory conditions.

04.

04. Industrial-Grade Integration

Once we've proven it can deliver, we bring the predictive system into the heart of your operations. Predictions flow into your SCADA, MES, ERP, and CMMS, and actions are triggered right from within the tools your teams use every day. We want predictive maintenance to become a seamless part of your daily routine, not some bolt-on extra.

05.

05. Multi-Line / Multi-Site Rollout

With a proven integration pattern, we standardize mappings, pipelines, and deployment templates so predictive maintenance programs can scale cleanly across additional lines or sites without redesign.

06.

06. Continuous Optimization

After rollout, predictive maintenance IoT architecture continues to evolve. We track drift, retrain models, and adjust logic as your equipment, production mix, or operational processes change. PdM remains aligned with real factory behavior rather than degrading over time.

  • 01. Technical Due Diligence

  • 02. Infrastructure Readiness

  • 03. Live Equipment Validation

  • 04. Industrial-Grade Integration

  • 05. Multi-Line / Multi-Site Rollout

  • 06. Continuous Optimization

Benefits

The Reliability Behind Predictive Maintenance

01

Operational Truth Precision

Predictive Maintenance works best when a system actually knows what's going on with your equipment — how it performs under real loads, through real shifts, with real operators on the job. We're talking about getting a full picture of what's going on, from the control logic to all those undocumented routines and performance drifts that mess with production. This highlights the benefit of predictive maintenance, eliminating guesswork inside the predictive layer and giving you models aligned to physical reality, not idealized data sheets.

02

Integration Without Friction

Predictive Maintenance will only pay off if it fits in with the way you're already working, and keeps up when things change. We design open, protocol-agnostic, evolution-ready architectures recognized across the predictive maintenance industry, integrating gracefully with SCADA, MES, ERP, CMMS, IoT sensors, and legacy assets. And it doesn't matter if new equipment comes online, or new rules come along — our system just adapts, no downtime, no need to start from scratch. That way, you can keep on getting value out of your Predictive Maintenance without it falling behind.

03

Enterprise-Grade Reliability

Devox stands among leading predictive maintenance companies, ensuring every deployment meets strict enterprise-level security and reliability expectations, from encryption and compliance to hardened OT/IT connectivity. But robustness extends beyond infrastructure: we also embed the reasoning of your top engineers directly into your system. We capture the expertise of your top engineers and embed it directly into the system. And then some, we use digital twins and all that AI jazz to dig up better ways of doing things that just get smarter and smarter over time.

Built for Compliance

Industry Regulations We Master

We follow the full compliance stack from the first architecture decision to every release — stable, audit-ready, and engineered for long-term scale.

[Industrial Security & OT/IT Safety Standards]

  • IEC 62443

  • NIST 800-82

  • ISO 27001:2022

  • ISA-95

  • CISA ICS Guidance

[Asset Management & Maintenance Standards]

  • ISO 55000 / 55001

  • ISO 14224

  • SAE JA1011 / JA1012 (RCM)

  • API RP 581

[Reliability, Failure Analysis & Safety Frameworks]

  • FMEA / FMEDA

  • AIAG-VDA

  • ISO 13849-1

  • IEC 61508

  • ISO 31000

[Data Protection & Operational Privacy]

  • GDPR

  • CCPA

  • ISO 27701

  • NIST Privacy Framework

[Industrial Communication & Integration Protocol Standards]

  • OPC UA

  • MQTT 5.0

  • Modbus/TCP

  • PROFINET

  • EtherNet/IP

  • ISA-95 Level Mapping

[Cloud, Infrastructure & Deployment Compliance]

  • ISO 27017

  • ISO 27018

  • SOC 2

  • CIS Benchmarks

  • Shared Responsibility Models

[AI Governance for Predictive Systems]

  • EU AI Act (2024/1689)

  • NIST AI RMF 1.0

  • ISO/IEC 42001 (AI Management)

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Testimonials

Testimonials

Carl-Fredrik Linné                                            Sweden

The solutions they’re providing is helping our business run more smoothly. We’ve been able to make quick developments with them, meeting our product vision within the timeline we set up. Listen to them because they can give strong advice about how to build good products.

Darrin Lipscomb Darrin Lipscomb
Darrin Lipscomb United States

We are a software startup and using Devox allowed us to get an MVP to market faster and less cost than trying to build and fund an R&D team initially. Communication was excellent with Devox. This is a top notch firm.

Daniel Bertuccio Daniel Bertuccio
Daniel Bertuccio Australia

Their level of understanding, detail, and work ethic was great. We had 2 designers, 2 developers, PM and QA specialist. I am extremely satisfied with the end deliverables. Devox Software was always on time during the process.

Trent Allan Trent Allan
Trent Allan Australia

We get great satisfaction working with them. They help us produce a product we’re happy with as co-founders. The feedback we got from customers was really great, too. Customers get what we do and we feel like we’re really reaching our target market.

Andy Morrey                                            United Kingdom

I’m blown up with the level of professionalism that’s been shown, as well as the welcoming nature and the social aspects. Devox Software is really on the ball technically.

Vadim Ivanenko Vadim Ivanenko
Vadim Ivanenko Switzerland

Great job! We met the deadlines and brought happiness to our customers. Communication was perfect. Quick response. No problems with anything during the project. Their experienced team and perfect communication offer the best mix of quality and rates.

Jason Leffakis Jason Leffakis
Jason Leffakis United States

The project continues to be a success. As an early-stage company, we're continuously iterating to find product success. Devox has been quick and effective at iterating alongside us. I'm happy with the team, their responsiveness, and their output.

John Boman John Boman
John Boman Sweden

We hired the Devox team for a complicated (unusual interaction) UX/UI assignment. The team managed the project well both for initial time estimates and also weekly follow-ups throughout delivery. Overall, efficient work with a nice professional team.

Tamas Pataky Tamas Pataky
Tamas Pataky Canada

Their intuition about the product and their willingness to try new approaches and show them to our team as alternatives to our set course were impressive. The Devox team makes it incredibly easy to work with, and their ability to manage our team and set expectations was outstanding.

Stan Sadokov Stan Sadokov
Stan Sadokov Estonia

Devox is a team of exepctional talent and responsible executives. All of the talent we outstaffed from the company were experts in their fields and delivered quality work. They also take full ownership to what they deliver to you. If you work with Devox you will get actual results and you can rest assured that the result will procude value.

Mark Lamb Mark Lamb
Mark Lamb United Kingdom

The work that the team has done on our project has been nothing short of incredible – it has surpassed all expectations I had and really is something I could only have dreamt of finding. Team is hard working, dedicated, personable and passionate. I have worked with people literally all over the world both in business and as freelancer, and people from Devox Software are 1 in a million.

FAQ

Frequently Asked Questions

  • What is AI-powered predictive maintenance, and how is it different today?

    The smart predictive maintenance system captures real operational behavior, becomes self-optimizing and grows stronger with every production cycle. Automated FMEA, reasoning models, and sensor-fusion pipelines turn noisy, inconsistent signals into a continuously learning reliability layer instead of a static model frozen at deployment.

    And here’s where it becomes operationally transformative. Traditional reactive or preventative maintenance systems follow fixed rules and intervals, while AI-driven PdM follows the real physics of your production. It synchronizes vibration, acoustics, energy profiles, MES timelines, and SCADA states into one decision fabric that adapts as the plant evolves. The value doesn’t sit in dashboards — it flows into workflows, triggering CMMS tasks, adjusting maintenance strategies, and aligning actions with real-time process context. With Lighthouse sites now deploying AI use cases 25% faster and often skipping pilots entirely, predictive maintenance has shifted from a standalone project to a production-grade operational system that strengthens with every cycle, every shift, and every new data point.

  • What data is required to build an accurate predictive maintenance system?

    Great question — teams often wonder what kind of data makes a predictive maintenance system truly accurate. The answer always begins with understanding how a machine behaves when it’s doing real work.

    High-accuracy predictive maintenance systems grow from datasets that reflect real operational behavior — not lab simulations. When you layer vibration, acoustics, thermal data, power draw, pressure shifts, SCADA events, MES timing, and operator inputs, you see the real behavior of the equipment — the tiny patterns that tell you how healthy it actually is. Lighthouse manufacturers show that high-value insights often emerge from the quiet zones between signals: drift patterns, asynchronous timestamps, subtle shifts during different shifts or product mixes, and long-term behavioral fingerprints formed over years of production. Sensor fusion elevates this landscape by merging acoustic, thermal, electrical, and operational inputs into a unified predictive maintenance and condition monitoring flow dense with context.

    Predictive precision depends on a strong edge pipeline that filters, aligns and enriches high-frequency signals before they reach cloud analytics. ML models get dramatically better when core signals are enriched with real ops data, from maintenance logs and failure tickets to operator notes, shift patterns, batch history, and MES/SCADA events. When telemetry lines up with real operating context, the model sees the asset’s true state, holds its accuracy as conditions shift, and flags early signs of wear before they turn into real problems.

  • How do we assess readiness for implementing an AI-enabled PdM system?

    Readiness for AI in maintenance starts with a clear view of how data, people, and processes interact in day-to-day operations. Technical due diligence maps the real operational landscape: data paths across SCADA, MES, PLCs, and sensors; undocumented logic created by years of operator practice; system bottlenecks that shape signal quality; and integration constraints across legacy and modern assets. This phase also evaluates data stability — timestamp alignment, sensor drift behavior, edge-pipeline strength, historical maintenance records, and the consistency of failure logs. Once the landscape is clear, artificial intelligence for predictive maintenance takes that visibility further, exposing process gaps and building trust between teams and algorithms.

    Once the technical foundation is visible, the next thing teams usually want to understand is how prepared the organization itself is to work with AI-driven insights. A second layer focuses on organizational and workflow readiness. Teams progress fastest when frontline operators, technicians, and engineers share a unified understanding of failure modes, reporting practices, and intervention rhythms. Lighthouse sites demonstrate that talent maturity — structured onboarding, SOP clarity, and the availability of digital guidance — amplifies the value of every prediction. System readiness follows the same pattern: MES/SCADA event structures, CMMS update hygiene, and cross-department alignment form the operational backbone for AI-driven actions. When these elements are synchronized, an AI-enabled PdM system lands in an environment capable of absorbing insights, executing interventions, and scaling improvements across sites.

  • How does an AI-based PdM system integrate into existing operational workflows?

    Leading predictive maintenance companies now design integration patterns that fit directly into real plant rhythms. That’s where the real integration story begins. Their experience defines much of today’s predictive maintenance industry, where interoperability with SCADA, MES, ERP, and CMMS has become standard practice. The system maps equipment hierarchies, process states, and event timelines directly to prediction logic, allowing each model output to inherit the full context of the production moment. SCADA tags, MES batch markers, machine states, shift transitions, and control-loop behavior converge into a unified event fabric where predictions align with what the plant is actually doing at that second. Lighthouse manufacturers highlight this as a turning point: once PdM understands the operational rhythm encoded in these systems, every alert carries actionable meaning rather than isolated analytics.

    And once that rhythm is clear, the next part of the conversation naturally moves to how the system supports the actions teams take throughout the day. Execution happens through event-driven orchestration. Predictions route into ERP and CMMS with the same precision as native operational triggers, generating work orders, adjusting priorities, or prompting material planning based on model confidence and lead-time windows. MES timelines provide the structure for synchronizing interventions with batch cycles or changeovers, while SCADA bridges handle real-time interactions across control layers. This orchestrated flow transforms PdM from a monitoring tool into an operational partner: a system that evaluates signals, initiates actions, and guides teams through the same channels they already trust, scaling seamlessly across assets and sites.

  • What AI models and diagnostic intelligence approaches are used?

    There’s a certain clarity that appears once you look at how predictive intelligence understands equipment in motion.

    Modern methods of predictive maintenance combine signal correlation, reasoning models, and GenAI-based diagnostic logic read equipment behavior like an experienced engineer and surface clear causal explanations for every prediction.

    From there, the next question is how this intelligence stays sharp as the environment changes. You can’t just rely on the diagnostic intelligence to keep working when the plant is changing all the time. You need to keep a close eye on how the models are performing – that’s what drift monitoring does. It’s the bit that tracks changes in sensor readings, operating conditions and process performance, and then flags up if anything’s starting to go wrong with the data or the equipment. Then there’s the automated retraining of the models to make sure they stay aligned with what’s actually going on in the factory. And when you combine that with some explainability tools and the ability to keep a record of decisions, you get a diagnostic layer that’s transparent, trustworthy and gets better all the time.

  • What ROI can companies expect from AI-based predictive maintenance?

    The main benefit of predictive maintenance becomes obvious in the first quarter of deployment — reduced downtime, lower energy waste, and faster decision loops. It’s completely natural to wonder what the real payoff looks like. Teams want to see results they can feel on the floor — in time saved, smoother shifts, and fewer frantic moments. That’s exactly where the impact starts to show. AI-based predictive maintenance delivers ROI by compressing intervention time, stabilizing production rhythms, and scaling expert-level decision quality across every shift. Lighthouse manufacturers provide a clear benchmark: MTTR drops by roughly 40% once genAI-assisted diagnostics begin interpreting SOPs, maintenance logs, and real operating patterns. This maintenance prediction capability shortens the window between anomaly detection and corrective action, raising line availability and lifting overall throughput. Plants that adopted AI-driven troubleshooting saw diagnostic cycles shrink from hours to seconds, creating measurable gains in uptime and freeing engineering talent for higher-value work.

    As early-stage degradation becomes visible across multi-sensor signals, unplanned downtime drops and the financial upside compounds with every additional asset. When AI-driven predictions feed straight into CMMS and ERP, you start cutting labor, parts, energy, and downtime at the same time — and the ROI keeps climbing as more assets come under the predictive layer.

  • Why do many PdM initiatives fail — and how does AI solve the real root causes?

    PdM fails when it’s built on idealized blueprints; AI works only when it interprets real-world operational noise and drives decisions into SCADA, MES, ERP, and daily workflows.

    And once you’ve got a good grasp on just how broken the system is, the path forward gets a whole lot clearer. So, how does AI actually solve these structural issues? For a start, it grounds predictions in the real behaviour of the factory, not some idealized rules that don’t apply anywhere in the real world. This means that the  AI for predictive maintenance can read over the SOPs, maintenance logs, company policies, and all that, and turn the accumulated knowledge of the organisation into real-time diagnostic reasoning that’s actually how the top techs think. This gives instant clarity on what’s gone wrong, and lets you get in there fast to fix it — and that leads to huge reductions in Mean Time To Repair (MTTR) and all this downtime that’s such a pain in the neck. And then there’s the drift tracking, automated Failure Mode and Effects Analysis (FMEA), and adaptive retraining – all this keeps the predictive layer up to speed with how the equipment is behaving, the loads it’s under, and the products its making. Event-driven orchestration is the icing on the cake – this means that each prediction can trigger a proper workflow that gets pushed out across SCADA, MES, ERP and CMMS. The end result of all this? PdM swings from being an isolated tool that’s just gathering dust, to becoming an integral part of the operation — a capability that gets stronger with every cycle.

  • How does the architecture evolve as operations change?

    PdM architecture evolves through protocol-agnostic edge ingestion, a shared asset model and loosely coupled services that let new sensors, models and KPIs plug in without touching SCADA, MES, ERP, or CMMS.

    And as operations scale across multiple sites, the conversation naturally widens to how the architecture supports growth without slowing teams down. Across multiple sites evolution-ready design becomes even more important. A central platform holds the shared data model, model registry, and orchestration, while each plant uses a local adapter to map its tags and assets. New sites onboard through blueprints — standard sensors, validated pipelines, and reference workflows. Centralized governance with edge execution lets you handle regulatory or product changes through config and model updates. Over time, every improvement at one site becomes a capability for the entire network.

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