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Leverage Sensor Data to Minimise Downtime and Optimise Maintenance

Reduce Equipment Downtime and Maintenance Cost Using Sensor Data

Analyse machine sensor readings, failure indicators, and maintenance history to improve uptime and preventive planning for PrimeAxis Manufacturing Solutions.

Manufacturing Difficult 90 min
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Why this work was commissioned

PrimeAxis Manufacturing Solutions Pvt. Ltd. operates multiple production lines where unplanned machine failures directly impact output and cost. Plant leadership requires data driven insight into equipment behaviour, failure patterns, and maintenance timing to reduce downtime and optimise preventive maintenance schedules.

Revolutionary Active Learning

  • You are expected to analyse sensor variables, machine conditions, failure flags, and operating hours.
  • The work must identify early warning signals, high risk machines, and maintenance triggers that support proactive intervention rather than reactive repair.

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Skills that will help before starting:

  • Excel data analysis
  • Basic understanding of operations metrics
  • Ability to interpret sensor data

Skills you will learn and practice:

Operational Data Analysis Failure Pattern Detection Downtime Impact Assessment Maintenance Strategy Framing
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Why This Simulation Works

Operations Critical

  • Insights directly reduce downtime and losses.

Data Driven Reliability

  • Maintenance decisions guided by measurable signals.

Action Ready

  • Outputs can be applied on the shop floor.

Simulation Breakdown

1 Excel Review Machine Sensor Dataset
  • Understand sensor variables and failure flags
  • Validate missing or abnormal readings
2 Excel Analyse Machine Operating Behaviour
  • Compare normal versus failure conditions
  • Identify threshold patterns
3 Excel Identify High Risk Equipment
  • Rank machines by failure frequency
  • Assess operating hour impact
4 Excel Evaluate Preventive Maintenance Triggers
  • Identify early warning indicators
  • Recommend maintenance timing
5 Excel Prepare Maintenance Intelligence Outputs
  • Draft maintenance analysis memo
  • Create executive presentation for plant leadership
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