Solution
Predict asset problems earlier and plan maintenance smarter.
Critical assets often show weak signals before failure. Intelecy helps reliability and maintenance teams use process data to detect developing faults, forecast risk, and plan intervention before unplanned downtime occurs.
The problem
What makes this operationally expensive today.
Reactive maintenance
Critical assets fail without warning; emergency callouts burn parts, shifts, and trust.
Weak early signals
Vibration, current, pressure, and temperature drift quietly long before alarms trip.
Unplanned downtime
Even a few hours of stoppage on a constraint unit destroys the monthly plan.
Signals we monitor
The process indicators behind every recommendation.
Intelecy reads these signals from your Historian, DCS, and SCADA — no new sensors required to get started.
How Intelecy solves it
From signal to action, mapped to the modules.
STEP 01
Establish per-asset healthy envelopes
Use Data Explorer to define what normal looks like for compressors, pumps, gearboxes, mills, or turbines.
STEP 02
Detect developing faults
Multivariate residual models flag drift early — with the top contributing variables operators can investigate.
STEP 03
Forecast time-to-event
Project residual trajectories so maintenance can schedule intervention in a planned window.
STEP 04
Route to the right team
Severity tiers, ownership rules, and CMMS hand-off keep reliability work where it belongs.
Expected KPIs
How customers measure success.
Avoided downtime
▲hrs/yr
vs maintenance baseline
MTBF
▲hrs
Per critical asset
Emergency callouts
▼/qtr
Reactive work orders
Planned-to-reactive ratio
▲%
Reliability program health
Proof
Reliability program, process plant
Reliability & maintenance
“We catch bearing degradation a week before it would have tripped the line — every time, on every machine class.”
Headline result
[verified metric]
downtime avoided in 12 months
Implementation
What it takes to stand this up.
Data needed
20–40 tags per critical asset (vibration, current, temp, pressure, flow) from your Historian; CMMS work-order history optional.
Timeline
First model live in 1 week; full fleet rollout in a quarter.
Stakeholders
Reliability lead, maintenance planner, process engineer, plant IT/OT.
Integration
Read-only Historian / DCS access via Gateway. Alerts to email, Teams, or CMMS (e.g. SAP PM, Maximo).
See it on your own plant data.
A 30-minute working session with our process AI team. Bring a unit, a goal, and a few tags — leave with a working model proposal.