The machine tells you first
Predictive maintenance across twelve plants, four continents.
GLOBAL AUTO MANUFACTURER · 12 PLANTS // 28 WEEKS // BOLT GROUP
A global automaker was losing $50 million a year to unplanned equipment failures. Traditional scheduled maintenance was either too frequent — wasting 30% of the budget on healthy machines — or too late, causing cascading line shutdowns. Ten thousand sensors were generating data. Nobody was listening.
- client
- Global Auto Manufacturer · 12 plants
- duration
- 28 weeks
- services
- IoT, Edge AI, Digital Twins
- sector
- Manufacturing & Industrial
Four moves, built to compound.
- 01
Edge sensor network
Edge nodes at each plant collect and pre-process vibration, temperature, pressure, and acoustic data from 10,000+ sensors in real time.
- 02
Failure prediction
Deep learning models trained on 5 years of failure data identify degradation patterns 48–72 hours before failure occurs.
- 03
Prioritized alerts
Alerts factor failure probability, production impact, spare parts availability, and crew scheduling into a single ranked feed.
- 04
Digital twins
3D digital twins of critical equipment with live health scores, anomaly visualization, and maintenance recommendations.
- Principal-ledSenior engineers and architects on the keyboard from week one. No staffing pyramid, no handoffs to juniors mid-engagement.
- Production-firstEvery artefact ships behind a load balancer. We measure success in throughput, latency, and uptime — not slides.
- Outcome-boundScope, milestones, and acceptance criteria locked at kickoff. We commit to the metric that moves your P&L.
- 01Apache Kafka
- 02TensorFlow
- 03PyTorch
- 04NVIDIA Jetson
- 05Kubernetes
- 06InfluxDB
- 07Grafana
- 08Azure
What shipped. In production.
"Every prevented failure makes the model smarter, which makes the next failure less likely. Predictive maintenance is the rare operational lever with compounding returns."
Three shapes. One delivery standard.
Defined outcome. Fixed price.
We scope, build, and ship a discrete production system end-to-end. Best when the brief is sharp and the deadline is real.
Embedded pod. Monthly cadence.
A senior pod plugs into your team for a multi-quarter horizon. Roadmap evolves; the engineers stay constant.
Senior eyes. Surgical scope.
Architecture review, model audit, or technical due diligence. Days to weeks. Written recommendations, not slideware.
Let's build what's next.
No SDR queue. No discovery deck. Pick a slot or send a note — Dean replies within four business hours.