OptimalTREND™ Wiki / Value and deployment
Value and config
Value and deployment
What predictive maintenance returns, and what it takes to run it. Value first, then the data and infrastructure in general terms.
Potential value
Confirmed Optimal client ranges, shown for context, not a per-site guarantee. Predictive maintenance moves the availability and maintenance-cost levers hardest by converting unplanned failures into planned work.
Why it pays
An unplanned failure costs the repair, the lost production, the collateral damage and the safety exposure, all at once and at the worst time. Catch the same failure weeks earlier and it becomes a scheduled job in a planned window at a fraction of the cost. Multiply across a fleet of critical assets and the availability and cost lines both move.
What it takes: the data
OptimalTREND™ is sensor-agnostic. It needs a signal that reflects asset condition over time, from one or more of:
- Existing sensors, historian or SCADA – vibration, temperature, motor current, pressure, flow, load and speed already being measured;
- Added sensing only where a critical asset is blind – a vibration or temperature node on the equipment that matters.
Config to deliver value (general)
| Data sources | Connect the existing historian, SCADA or sensors of any brand; add dedicated nodes only on critical, unmonitored assets. |
|---|---|
| Edge and connectivity | A gateway collects new sensing where needed; existing data is pulled from the historian or control system. Brownfield-friendly, minimal cabling. |
| Secure ingestion and models | Signals stream over a secure channel into the analytics engine, which learns the baseline and runs the anomaly and prognostics models per asset. |
| Portal, mobile and CMMS | Health, alerts and remaining useful life surface in the portal and the Flutter mobile app, and push work orders to your maintenance system. |
General architecture only. A criticality assessment sets which assets are monitored first and with what.
A typical path
Start with the critical assets: connect their existing data, learn the baselines, and prove early warnings against real events. Bank the availability and cost gains on those, then extend across the plant. The demo runs the loop end to end on seeded assets so the shape is clear before any sensor.
Where do you stand?
Before you invest, the GARPI™ benchmark shows your asset-management maturity against industry peers: an independent, ISO 55001 and GFMAM-aligned score from 0 to 100 across eight weighted dimensions and five maturity tiers, free and anonymous. It is a fast way to see where you are today, and where OptimalTREND™ moves you first. Take the GARPI™ benchmark.