Live Demo · Predictive Maintenance Engine

MHE Fleet Health Monitor

Simulated IoT feeds from 9 material handling assets. ML anomaly detection flags bearing wear, overheating events, and misalignment patterns before they cause unplanned downtime.

51
Fleet Health Score
9
Assets at Risk
$24,900
Predicted Savings
646
Active Anomalies

Active Alerts 9 assets

Sort Drive North WARNING
67 anomalies detected · ~1d to threshold
Forklift Bravo WARNING
74 anomalies detected · ~3d to threshold
Sort Drive East WARNING
66 anomalies detected · ~2d to threshold
Forklift Alpha WARNING
74 anomalies detected · ~4d to threshold
Forklift Charlie WARNING
66 anomalies detected · Monitor closely
Conveyor Motor 1 WARNING
79 anomalies detected · Monitor closely
Conveyor Motor 2 WARNING
64 anomalies detected · Monitor closely
Conveyor Motor 3 WARNING
93 anomalies detected · ~9d to threshold
Sort Drive South WARNING
63 anomalies detected · Monitor closely

Fleet Assets

54
Forklift Alpha
Electric Forklift · Receiving Dock
⚡ 2.62 mm/s 🌡 46.18°C
74
46
Forklift Bravo
Electric Forklift · Zone A Storage
⚡ 4.0 mm/s 🌡 35.5°C
74
55
Forklift Charlie
Electric Forklift · Shipping Dock
⚡ 1.47 mm/s 🌡 50.11°C
66
55
Conveyor Motor 1
Conveyor Motor · Inbound Line 1
⚡ 1.65 mm/s 🌡 52.22°C
79
55
Conveyor Motor 2
Conveyor Motor · Inbound Line 2
⚡ 1.88 mm/s 🌡 65.55°C
64
55
Conveyor Motor 3
Conveyor Motor · Outbound Line
⚡ 2.42 mm/s 🌡 74.6°C
93
40
Sort Drive North
Sortation Drive · Sort Zone North
⚡ 2.57 mm/s 🌡 103.44°C
67
55
Sort Drive South
Sortation Drive · Sort Zone South
⚡ 1.75 mm/s 🌡 52.14°C
63
46
Sort Drive East
Sortation Drive · Sort Zone East
⚡ 4.81 mm/s 🌡 73.49°C
66

Select an asset from the fleet list to view its sensor charts and maintenance recommendation.

Maintenance Schedule

Asset Type Location Health Priority Recommended Action Est. Cost
Sort Drive North Sortation Drive Sort Zone North 40 WARNING Alignment check and belt tension adjustment within 5 days. $1,800
Forklift Bravo Electric Forklift Zone A Storage 46 WARNING Schedule bearing inspection and lubrication within 7 days. $950
Sort Drive East Sortation Drive Sort Zone East 46 WARNING Alignment check and belt tension adjustment within 5 days. $1,800
Forklift Alpha Electric Forklift Receiving Dock 54 WARNING Schedule bearing inspection and lubrication within 7 days. $950
Forklift Charlie Electric Forklift Shipping Dock 55 WARNING Schedule bearing inspection and lubrication within 7 days. $950
Conveyor Motor 1 Conveyor Motor Inbound Line 1 55 WARNING Thermal inspection; check cooling fan and belt tension within 7 days. $1,400
Conveyor Motor 2 Conveyor Motor Inbound Line 2 55 WARNING Thermal inspection; check cooling fan and belt tension within 7 days. $1,400
Conveyor Motor 3 Conveyor Motor Outbound Line 55 WARNING Thermal inspection; check cooling fan and belt tension within 7 days. $1,400
Sort Drive South Sortation Drive Sort Zone South 55 WARNING Alignment check and belt tension adjustment within 5 days. $1,800

How the Detection Works

Each asset streams vibration, temperature, and acoustic readings at 15-minute intervals. Two statistical detectors run in tandem, then a composite health score and linear trend extrapolation drive prioritized work orders.

IoT Sensor Network
Accelerometers, RTDs, and acoustic emission sensors mounted at mechanical stress points — motor housings, gearboxes, and belt splice points — stream 15-minute telemetry to the edge processing layer.
Z-Score Detection
Each reading is scored against the global mean and standard deviation for that sensor/asset combination. Readings beyond ±2.5σ are flagged as global anomalies, catching sudden events like motor overheating.
Rolling Mean Deviation
A 20-point rolling window tracks local baseline behavior. Deviations beyond 2.5× the window σ surface gradual drift patterns — bearing wear, misalignment — that Z-score alone misses.
Health Score (0–100)
Composite score penalizes anomaly density (recent anomalies weighted 2×) and sensor proximity to failure thresholds. Fleet-level score is the unweighted asset average.
Days-to-Failure Forecast
Linear regression on the second half of the sensor series extrapolates the current trend to the failure threshold. Gives maintenance planners a specific scheduling window.
Prescriptive Work Orders
Health score and failure forecast map to a three-tier maintenance matrix: Critical (immediate), Warning (within 7 days), and Routine (next PM cycle) — with specific subsystem action and cost estimate.

See the full architecture behind this engine

The case study examines how Arc Data deployed a high-frequency IoT sensor network across a 3,000-forklift fleet — including the ML classification engine, edge processing layer, and prescriptive work order integration that shifted maintenance from reactive to prescriptive.

Read the Case Study