Predicting equipment failures before they cause downtime

Ferro Industrial had sensor telemetry scattered across a dozen plant-floor systems, none of which talked to each other. Maintenance was scheduled on fixed intervals rather than actual equipment condition.

We built unified feature pipelines on Azure that bring telemetry from across the plant floor into a single feature store, feeding models that flag developing equipment issues days before failure.

Unplanned downtime is down 23% since rollout, and the maintenance team now works from a prioritized, model-ranked queue instead of a fixed calendar.