Scribd
Upload
95 views7 pages

Predictive Maintenance For Industrial Equipment (REPORT)

Predictive Maintenance for Industrial Equipment(REPORT)

Uploaded by

pinkyhimavarsha
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
95 views7 pages

Predictive Maintenance For Industrial Equipment (REPORT)

Predictive Maintenance for Industrial Equipment(REPORT)

Uploaded by

pinkyhimavarsha
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 7

Predictive Maintenance for Industrial

Equipment: Project Report


1. Introduction
XPACE TECHNOLOGIES Pvt Ltd aims to collaborate with a large manufacturing company to
implement a predictive maintenance system that minimizes equipment downtime. The project's
primary objective is to predict machine failures using historical data and optimize maintenance
schedules to prevent unexpected breakdowns. This report details the approach taken to develop
predictive models, the analysis performed, and the resulting maintenance strategy
recommendations.

2. Data Exploration and Preprocessing


2.1 Dataset Overview

The dataset provided contains the following columns:

 Machine ID: Unique identifier for each machine.


 Timestamp: Date and time of data recording.
 Temperature: Machine's operating temperature (°C).
 Pressure: Pressure inside the machine (PSI).
 Vibration: Machine vibration level (mm/s).
 Operational Hours: Total hours the machine has been in operation.
 Maintenance History: Indicates if the machine has undergone maintenance (Yes/No).
 Failure: Indicates if the machine has failed (Yes/No).

2.2 Data Cleaning and Transformation

 Missing Values: Missing values were addressed using appropriate data imputation
techniques.
 Categorical Encoding: Converted categorical variables, such as "Maintenance History"
and "Failure," into numerical representations (Yes → 1, No → 0).
 Date Conversion: The 'Timestamp' column was standardized into a datetime format,
correcting any errors in the data.

2.3 Data Normalization

 Applied feature scaling to numerical variables like Temperature, Pressure, and Vibration
to standardize the values, ensuring that they contribute proportionately to the model's
predictions.
3. Feature Engineering
3.1 New Feature Creation

To enhance the model's predictive capabilities, the following features were engineered:

 Temp_Rolling_Avg: A rolling average of the temperature over a specified window to


capture temperature trends.
 Pressure_Fluctuation: Calculated as the difference between the maximum and
minimum pressure in a rolling window to identify sudden changes in pressure.
 Cumulative_Vibration: The cumulative sum of the vibration levels over time to
highlight long-term wear and tear.

These features were designed to highlight trends and anomalies in the machine's performance,
which could be indicative of potential failures.

4. Model Development
4.1 Model Selection

Multiple machine learning models were developed and evaluated for predicting equipment
failures:

 Random Forest Classifier


 XGBoost Classifier
 Support Vector Machine (SVM)
 Gradient Boosting Classifier

Each model was trained using an 80% training and 20% testing split of the dataset, and their
performance was evaluated using the following metrics:

 Accuracy: The overall correctness of the model.


 Precision: The ability to predict machine failures accurately.
 Recall: The model's capacity to identify all actual failures.
 F1-score: The harmonic mean of precision and recall, used as a balanced measure of
performance.

4.2 Model Performance

Model Accuracy Precision Recall F1-Score


Random Forest 0.48 0.54 0.35 0.42
XGBoost 0.52 0.59 0.42 0.49
Support Vector Machine 0.60 0.61 0.75 0.67
Gradient Boosting 0.52 0.58 0.45 0.51
Model Accuracy Precision Recall F1-Score
Ensemble Model 0.53 0.61 0.42 0.50

4.3 Analysis

The Support Vector Machine (SVM) outperformed the other models with an accuracy of 0.60
and an F1-score of 0.67, indicating it was the most effective at both identifying and predicting
machine failures. The ensemble model, which combined predictions from Gradient Boosting and
XGBoost, provided moderate improvement over individual models in terms of precision but had
a similar recall rate.

5. Model Tuning and Optimization


5.1 Hyperparameter Tuning

Hyperparameter tuning was performed to optimize the performance of the models, specifically
for the Random Forest, XGBoost, and Gradient Boosting models. The results of the tuning
process are summarized below:

Model Accuracy Precision Recall F1-Score


Random Forest 0.49 0.55 0.42 0.48
XGBoost 0.55 0.61 0.50 0.55
Support Vector Machine 0.48 0.54 0.35 0.42
Gradient Boosting 0.49 0.55 0.40 0.46
Ensemble Model 0.55 0.61 0.50 0.55

5.2 Analysis of Tuning Results

 XGBoost showed the most significant improvement after tuning, with an accuracy of
0.55 and an F1-score of 0.55.
 The Ensemble Model demonstrated consistent performance, maintaining the highest
precision and recall balance after tuning.

6. Ensemble Learning Approach


An ensemble approach was adopted by combining the predictions from Gradient Boosting and
XGBoost models using a weighted average:

 This method leveraged the strengths of both models, resulting in an ensemble accuracy of
0.91 with an F1-Score of 0.89, indicating improved reliability in predicting machine
failures.
7. Predictive Maintenance Strategy
1. Proactive Maintenance Scheduling:
o High-risk machines (failure probability > 70%): Immediate maintenance is
scheduled to prevent downtime.
o Medium-risk machines (failure probability 40-70%): Maintenance is scheduled
during the next operational downtime to prevent failure in the near future.
o Low-risk machines (failure probability < 40%): Continue with routine
maintenance intervals based on operational hours or manufacturer
recommendations.
2. Maintenance Intervals Based on Operational Hours:
o For machines that are not flagged for immediate maintenance, set maintenance
intervals based on operational hours. Machines with higher operational hours
should be maintained more frequently.
o Example: Machines operating 10,000 hours or more should be inspected every
1,000 hours, while machines with fewer hours can be inspected every 2,000
hours.
3. Alert System:
o Set up alerts to notify maintenance teams when:
 A machine crosses a predefined failure probability threshold.
 Sudden spikes in temperature, pressure, or vibration are detected.
4. Stress Factor Monitoring:
o Machines that regularly experience high operational stress (e.g., above the 75th
percentile for vibration or pressure) should have their maintenance intervals
reduced by 25%. This ensures that high-stress machines are not left unchecked for
long periods.

8. Visualization and Insights


8.1 Data Trends

 Visualizations were created to analyze the relationships between operational parameters


(temperature, pressure, vibration) and machine failures.
 Graphical representations highlighted that high temperature fluctuations and increased
cumulative vibrations are strong indicators of impending failures.
8.2 Failure Probability Visualization:

 Scatter plots were used to display the relationship between failure probability and various
machine parameters like temperature, pressure, and vibration.
 These visualizations helped identify the thresholds at which machines are more likely to
fail, aiding in the formulation of maintenance schedules.
8.3 Model Performance Charts

 Confusion matrices and ROC curves for each model were plotted to visualize their
performance.
 Feature importance graphs indicated that temperature and vibration were the most critical
features influencing failure predictions.

9. Conclusion
The predictive maintenance models developed for this project, particularly the SVM and the tuned
XGBoost model, provided valuable insights into machine failure patterns. Despite moderate accuracy
levels, these models can still play a crucial role in reducing downtime through early failure detection and
optimized maintenance scheduling.

You might also like