Predictive Maintenance — Bearing Failure Prevention
“Predict failures before they happen. Replace parts during planned stops.”
📖 The Scene
NayaCore detects bearing degradation 14 days before failure, fuses sensor data with human observations from WhatsApp, and schedules a planned repair — saving $14,000 in unplanned downtime.
Siti
Control Room Operator (T2.5)
📱 See It In Action
Real WhatsApp conversations between operators, supervisors, and NayaCore — in Bahasa Indonesia, exactly as they appear on the phone.
📈 Vibration trend naik
+0.30 mm/s per hari selama 5 hari
Saat ini: 6.3 mm/s (masih normal)
Prediksi: melewati batas 8.0 mm/s dalam ~6 hari
🔍 FFT: puncak di 48Hz (cocok dengan frek bearing inner race)
💡 Ini BUKAN alarm darurat. Ini peringatan prediktif — masih ada waktu untuk jadwalkan inspeksi.
Press #3 — Bearing Inner Race Degradation
📡 Sensor trend: +0.30 mm/s/hari (7 hari)
📱 Budi: "bearing kering, sisi kanan bawah"
📊 FFT: 48Hz peak (inner race signature)
Confidence: 87% (sensor + human fused)
⏰ TIMELINE PREDIKSI:
Hari ini: 6.9 mm/s (normal)
~4 hari: 8.0 mm/s (alarm)
~14 hari: 11.0 mm/s (bahaya)
💡 REKOMENDASI:
Jadwalkan penggantian bearing saat maintenance window berikutnya (sebelum hari ke-11).
Press #3 — Bearing diganti
📊 Vibration: 6.9 → 3.8 mm/s ↓45%
📊 FFT: bersih, tidak ada puncak
⏱️ Downtime aktual: 2.5 jam
📸 Foto: bearing lama menunjukkan pitting dan scoring
🔮 Prediksi AI vs aktual:
Akurasi: ✅ Dikonfirmasi
💰 Biaya tercegah:
Total saved: ~Rp 355M (~$22,100)16:45
From Vibration Signal to Prevented Shutdown
NayaCore detects bearing degradation 14 days before failure, fuses sensor data with human observations, and schedules a planned repair — saving $14,000 in unplanned downtime.
Trend Emerges
Press #3 vibration is at 6.3 mm/s (well below the 8.0 alarm limit). But NayaCore's trend engine notices it's rising by 0.30 mm/s per day. It sends an early warning to Siti.
Sensor-Human Fusion
Budi casually mentions a dry bearing noise in the field WhatsApp group. NayaCore extracts this, fuses it with the 48Hz FFT peak (BPFI inner race signature), and issues a high-confidence predictive alert.
Planned Maintenance & Validation
The bearing is replaced during a planned shift change (2.5 hours downtime vs 12 hours unplanned). When the machine restarts, NayaCore confirms the vibration dropped by 45% and logs the $22K ROI.
📊 Before vs. After
Traditional Operations vs. NayaCore
| Metric | Traditional | NayaCore |
|---|---|---|
| Detection method | Machine stops / smokes | Detected 7–21 days before failure |
| Downtime per event | 8–24 hours (emergency) | 2–4 hours (planned swap) |
| Revenue lost per event | ~$14,000 (unplanned) | $0 (planned during shift change) |