KAPL – Automotive Manufacturing
KAPL Automotive – Unlocking Predictive Power
Client:
KAPL, India – Leading automotive component manufacturer
Challenge:
Frequent unplanned equipment downtime disrupted production schedules, reduced profitability, and strained on-floor efficiency.
Solution:
MachineData.Ai was deployed with predictive maintenance capabilities using IoT-enabled sensors and AI-driven anomaly detection. Real-time data was collected from CNCs, welding units, and auxiliary systems to monitor health, load, and sequence cycles.
Key Features Used:
- Predictive Maintenance Agent
- Real-Time Machine Monitoring
- Shift & Utilization Analytics
- Automated Maintenance Alerts
Results:
- 30% reduction in unplanned downtime through early fault detection
- 20% increase in equipment lifespan, reducing frequent part replacements
- 12% increase in production output by optimizing maintenance schedules and shift planning
- Boosted overall profitability with real-time visibility into machine health
Conclusion:
With MachineData.Ai, KAPL moved from reactive repairs to proactive planning, achieving operational resilience and scalability.
Summary
Problem: Unplanned downtime affecting output!
Result:
✅ 30% less unplanned downtime.
✅ 12% production increase.
✅ 20% longer equipment lifespan.
