Predictive Maintenance with AI to Prevent Downtime and Failures

Building a Foundation for AI Success Across the Business. How a Machinery Manufacturer Reduced Unexpected Failures with ConnXions.

A North Carolina-based industrial equipment manufacturer experienced frequent, costly breakdowns across its fleet of aging machines. Even with a preventative maintenance schedule in place, unplanned downtime continued to disrupt operations, delay shipments, and inflate costs.

The Challenge: Maintenance Schedules Weren’t Enough

The maintenance team was diligent, but reactive. The biggest issues:

• Maintenance was based on static schedules, not real-time equipment health

• They lacked visibility into sensor data trends or failure patterns

• Technicians often performed unnecessary maintenance or missed urgent issues

These breakdowns weren’t just technical—they were affecting customer trust and revenue.

The Solution: AI-Powered Predictive Maintenance with ConnXions

The company partnered with ConnXions for a full AI Readiness Assessment. ConnXions:

• Audited the company’s machine data and IoT sensor capabilities

• Identified the highest-risk machines and failure patterns

• Recommended and helped implement predictive maintenance models

• Integrated AI dashboards with the company’s existing CMMS (Computerized Maintenance Management System)

The Impact: More Uptime, More Confidence

Within 90 days of implementation:

• Unplanned downtime dropped by 37%

• Critical maintenance alerts increased task prioritization

• Equipment lifespan increased through condition-based servicing

Why It Matters

AI helped this manufacturer go from reactive to predictive—resulting in a leaner, smarter, more reliable operation. With ConnXions, they didn’t just adopt AI—they aligned it with their business goals and infrastructure.

🚚 Curious if AI forecasting could work for your products too?

Let ConnXions show you where and how to start. Schedule a Free Forecasting Readiness Call