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

Case Study

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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