Abstract & Overview
Introduction This study explores the shift toward predictive maintenance through real-time data analytics to minimize machine downtime and improve machinery insights in industrial environments. Predictive maintenance aims to enable proactive interventions by predicting failures, enhancing operational efficiency. Methods The research was conducted in three stages. First, BA Glass equipment was sensorized using OPC Router and PowerStudio SCADA to facilitate real-time data extraction. A predictive maintenance algorithm was then developed in Python to analyze sensor data, predict failures, and trigger alarms. Finally, various forecasting models, including Linear and Polynomial Regression, Simple and Double Exponential Smoothing, ARIMA, and Prophet, were evaluated using a combination of blocked cross-validation and rolling window methodologies. The algorithm calculated performance metrics such as MSE, RMSE, and MAE for different parameter configurations and training sizes. Results A comparative analysis between wired and wireless sensors concluded that wireless sensors, although more expensive, were more practical and interchangeable in the factory setting. The results from the evaluation of prediction models showed that the Double Exponential Smoothing (DES) model with an additive damped trend and linear models performed best for datasets with daily seasonality and gradual oscillations. For datasets with stable trends and higher frequency oscillations, ARIMA and Prophet models proved to be more accurate. Discussion These findings suggest that the choice of sensors and prediction models can significantly impact the effectiveness of predictive maintenance systems. Wireless sensors offer long-term benefits in terms of flexibility and practicality, while the DES model and ARIMA/Prophet models are optimal depending on the dataset characteristics. This research highlights the value of real-time data analytics and predictive models in industrial environments for reducing downtime and improving decision-making.