Data-Driven Dynamic Maintenance Plans Reduce Expense of Replacing Parts Under Warranty for a global Manufacturer

Business Objective

Our client manufactures industrial inkjet printers for commercial customers for product labeling and also provides warranty/maintenance plans post-installation.

The client wanted to create customized maintenance plans and enable reliability engineers to embrace data-driven insights. They wanted to segment printers based on usage data and recommend personalized maintenance plans and build an end-to-end application to guide reliability engineers through the maintenance plan recommendation process.

Challenges

Data is collected from the devices directly by field technicians leading to a lot of data issues
Data available in multiple languages and different log templates based on machine configuration
Logs are collected only for ~3-5% of installed printers

Solution Methodology

Identified device characteristics from available data
Modeled stress parameters
Applied business logic to the imputed stress parameters. Stress parameters that were significant and independent were chosen for clustering.
Clustered the printers based on the parameters chosen into high/medium and low-stress conditions

Business Impact

Automated all existing manual processes along with new features to enable the client to generate personalized maintenance plans
Reduced expense of replacing parts under warranty for many customers due to static plans and estimated to generate additional revenue of $1 million per annum

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Data-Driven Dynamic Maintenance Plans Reduce Expense of Replacing Parts Under Warranty for a global Manufacturer

Business Objective

Challenges

Solution Methodology

Business Impact

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