Predictive maintenance
Predictive maintenance software that tells you what to fix next
AnalytIQ watches the condition of your rotating equipment 24/7 and ranks it by risk. You get early warnings, the reason behind them and a recommended action, so planned work replaces emergency repairs.
Maintenance strategies compared
| Strategy | When work happens |
|---|---|
| Reactive | After it breaks |
| Preventive | On a calendar, needed or not |
| Predictive | When the data shows it's needed |
The four building blocks of AnalytIQ predictive maintenance
1. Machine health score
A 0–100 score built from RMS velocity, acceleration, high-frequency energy, crest factor, kurtosis and temperature. It's weighted by a machine profile that captures machine class, mounting and operating speed, so a large pump isn't judged by the limits for a small fan.
2. Maintenance risk
Risk combines current severity, how fast it is changing and how long the machine has spent at elevated vibration. Each risk level lists the factors behind it, so planners can defend priorities in the morning meeting.
3. Anomaly detection
Every machine learns its own normal. Drift from that baseline is flagged even while readings are still inside ISO limits. That is often the earliest warning you'll get.
4. Insight & recommended action
Instead of "X-axis 4.2 mm/s", you see "Rising high-frequency vibration on the drive end. Check lubrication and bearing condition at the next stop."
What changes in your maintenance team
- Morning review in 10 minutes: a fleet list sorted by risk replaces walk-around routes.
- Parts ordered ahead: lead time from detection lets you buy bearings at normal prices, not emergency ones.
- Repairs in planned windows: combine jobs during scheduled stops instead of unplanned shutdowns.
- Proof after the fix: vibration drops back to baseline, confirming the repair worked.
- Knowledge that stays: event history per machine survives staff turnover.
A realistic rollout
- Week 1: criticality ranking and pilot asset list
- Week 2: sensors installed, dashboards live
- Weeks 3–4: baselines learned, alert thresholds tuned with your team
- Month 2+: weekly risk review becomes routine. Expand to more assets and add power monitoring.
Frequently asked questions
What is the difference between preventive and predictive maintenance?
Preventive maintenance is done on a fixed schedule, such as every 3,000 running hours, whatever the machine's condition. Predictive maintenance uses condition data such as vibration, temperature and current to service equipment only when it shows signs of degradation, before it fails.
How long before AnalytIQ can predict problems?
Severity zones and health scoring work from the first reading because they use standard limits for the machine class. Anomaly detection needs a period of normal operation to learn each machine's baseline, typically several days of representative running.
Does predictive maintenance replace our CMMS?
No. AnalytIQ tells you which asset needs work and why. Your CMMS still manages work orders, spares and labour. Data can be exported so planners can raise work orders from AnalytIQ insights.
Which assets should we start with?
Start with assets where a failure stops production, is expensive to repair, or is a safety risk, and which have no redundancy. A short criticality ranking with your maintenance team usually identifies 5–20 good pilot candidates.
See your own machines on AnalytIQ in 30 minutes
Book a live demo. We'll walk through vibration, health scoring and energy dashboards on real plant data, then scope a pilot on one or two of your critical assets.