Predictive maintenance & PLC integration
The machine talks. We listen before it fails.
Vibrations, temperatures, current draw, cycles: PLCs produce every day the data needed to predict a failure. We acquire it, model it and turn it into useful alerts — integrated with MES and ERP, not yet another dashboard to ignore.
In practice
Acquisition
Connection to PLCs via OPC UA, S7 and Modbus TCP, local buffering, historization: machine data becomes an asset, not a log that gets lost.
Health-state models
Learning normal operation (autoencoders, Isolation Forest, time-series models) and early detection of the deviations that precede a failure.
Alerts that matter
Adaptive thresholds, priorities, anomaly explanations: the operator knows what to look at. False alarms measured and reduced over time.
IT/OT integration
Maintenance orders in the MES/ERP, spare parts, intervention history: the prediction closes the loop with the people doing the work.
Stack and technologies
- Siemens S7
- OPC UA · Modbus TCP
- MQTT
- PyTorch
- Grafana
- Docker
Project
In developmentIntegration with Siemens PLCs
Project currently in development: signal acquisition from Siemens PLCs, historization pipeline and anomaly detection models for predictive maintenance, connected to management systems. The same time-series and anomaly models already in production in GA.IA.
- PLC
- Siemens
- Protocols
- OPC UA · S7 · Modbus
- Models
- anomaly detection · time series
- Status
- in development
How we work
Four steps, always the same
- 01
Map of available signals and historical failures
- 02
Acquisition and historization, first baseline of "normal"
- 03
Models and alerts, validated with maintenance staff
- 04
MES/ERP integration and continuous improvement
Frequently asked questions
Are new sensors required?
Often not: the data already present in the PLCs is enough for a first baseline. We add sensors (vibration, current, acoustics) only where the expected value justifies it.
Which PLCs do you work with?
Siemens first of all (integration in development) and, in general, PLCs that expose OPC UA or Modbus TCP.
Related capabilities
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