Industrial Predictive Maintenance
Anticipate failures and maximize the reliability of your facilities with real-time data.
What is Industrial Predictive Maintenance?
Predictive maintenance has become a fundamental pillar of Industry 4.0, making it possible to detect failures before they occur thanks to advanced analysis of industrial data. Improve the availability of your assets, reduce operating costs, and optimize intervention planning with a strategy based on real data.
Main Functions
Real-time Monitoring of Condition Sensors
Continuous capture of data (vibration, temperature, ultrasound, current, wear particles) through IoT sensors installed in critical equipment.
Intelligent Industrial Data Collection
Automated and continuous collection of key variables (vibrations, temperature, cycles, consumption, etc.) from multiple sources: IoT sensors, SCADA, MES, and PLCs. This robust database allows building a reliable technical history of each piece of equipment.
Advanced Analysis with AI and Predictive Models
Application of machine learning algorithms and statistical analysis to detect hidden patterns, deviations, or symptoms of failure. Breakdowns, quality defects, or loss of performance are anticipated.
Technical Pilot and Scalable Deployment
Initial implementation in a controlled environment (pilot test) that validates technical feasibility, evaluates available sensors, and defines the roadmap for scaling to the rest of the lines or plants.
Real-time Visualization and Reporting
Dashboards adapted to different profiles (maintenance, production, management) with KPIs such as asset status, alerts, failure predictions, and recommendations. Integration with CMMS for automatic orders.
Early Activation of Alerts and Interventions
Issuance of intelligent alerts before a critical failure occurs. The system recommends preventive actions or automatically generates work orders, reducing intervention costs and downtime.
Challenges We Solve
Challenges
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Does your factory suffer unexpected stoppages that slow down production and drive up costs?
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Do you still do reactive maintenance, without knowing when a critical machine may fail?
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Is it difficult for you to justify the expense of spare parts or the replacement of components ahead of time?
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Don’t you know where to start to implement a maintenance 4.0 strategy?
Predictive maintenance allows you to anticipate failures before they occur, extending the useful life of your assets, reducing stoppages, and optimizing operating costs.
Benefits
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Improved overall reliability
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Reduction of the annual intervention rate
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Improved safety and reduction of accidents
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Decrease in spending on spare parts
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Optimization of the life cycle cost of assets
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Reduction of serious failures thanks to the continuous use of data
Anticipate critical failures with predictive maintenance
Talk to an expertRelated Solutions and Services
MES – Manufacturing Execution System
Geprom’s MES is designed to act as the central hub of industrial operations, integrating with automation (SCADA, PLC), business (ERP), and support (quality, maintenance, logistics) systems. Its modular architecture allows for flexible scaling, from data capture to complete traceability.
- Native integration with SCADA/DCS for real-time data capture
- Connection with ERP for orders, stocks, and reporting
- Interoperability with quality, traceability, CMMS, and WMS modules
- Validation in SAP, Microsoft, SAGE, etc. environments
- Multi-site and multi-plant architecture
Energy Efficiency Software
Integration with CMMS, MES, SCADA, and electrical devices
Connected, supervised, and optimized energy in real time
Geprom’s energy efficiency software integrates with the rest of the plant architecture to provide a complete view of consumption. It connects with SCADA to acquire electrical data, with CMMS to optimize maintenance, and with MES to correlate consumption with productivity.
- Captures data from SCADA and electrical sensors
- Crosses energy consumption with OEE, batches, or shifts via MES
- Integration with CMMS for predictive energy maintenance
- Compatible with ISO audits and industrial energy regulations
APS – Advanced Planning and Scheduling
Integration with other systems (ERP, MES, SCADA, QMS, WMS)
Global vision and optimized production scheduling
Geprom’s APS system allows you to plan and sequence manufacturing orders considering the actual plant capacity and the restrictions of materials, machines, and personnel. Its integration with ERP, MES, and other industrial systems ensures dynamic, accurate planning aligned with the operation.
- Bidirectional connection with ERP (SAP, Dynamics, Oracle, SAGE, etc.)
- Real-time synchronization with MES for production execution
- Simulation of productive digital twin type scenarios
- Flexible programming in multiline and multiplant environments
- Resource optimization and bottleneck reduction
SCADA – Supervisory Control and Data Acquisition
Integration with PLC, MES, DCS and ERP
Total supervision and base for industrial digitization
Geprom’s SCADA system connects with plant devices (PLCs, sensors, actuators) and feeds data to systems such as MES or ERP. It is the basis of real-time supervision and a key pillar for the deployment of MOM architectures.
- Direct communication with PLCs and DCS
- Synchronization with MES for recipe control, alarms, and OEE
- Export of historical data to ERP or BI
- Flexibility to connect to existing sensors, HMI interfaces, and control systems
WMS – Warehouse Management System
Integration with ERP, MES, and IoT devices
Logistics and production synchronized in real time
Geprom’s WMS system integrates with the ERP to manage orders, stocks, and work orders, and with the MES to coordinate inputs, consumption, and returns. In addition, it connects with sensors, RFID tags, and logistics automation technologies (robots, AGVs, automatic shelving).
- Connection with MES for operational traceability and production orders
- Integration with ERP for logistics and finance
- Interoperability with RFID, barcodes, NFC, AGVs
- Advanced management of picking, returns, cross-docking
- Total logistics visibility from plant to dispatch
CMMS – Computerized Maintenance Management System
Integration with MES, ERP, WMS and IoT devices
Connected maintenance for a more efficient factory
Geprom’s GeTag CMMS software integrates in real time with MES, WMS and ERP to consolidate all information related to assets, maintenance, parts and resources. Its open architecture allows the incorporation of predictive maintenance technologies and advanced analytics.
- Connection with ERP for purchases, stocks, costs and planning
- Integration with MES for planning productive maintenance
- Synchronization with WMS for parts, technical warehouse and spare parts
- Connectivity with sensors, IoT, NFC/RFID tags
- Prepared for predictive maintenance and advanced analytics
QMS – Advanced Quality Management Software
Integration with MES, ERP, and inspection systems
Connected quality control and total traceability
QMS connects with MES and ERP to ensure a continuous flow of data between production, quality, and business. In addition, it integrates with LIMS systems, measuring devices, and artificial vision, capturing key parameters in real time to ensure product and process conformity.
- Direct interface with MES to activate automatic controls
- Synchronization with ERP for document and batch management
- Integration with sensors, scales, artificial vision, SCADA
- Compatible with ISO, FDA 21 CFR Part 11 standards
- Connectivity with laboratory systems (LIMS)
Industrial Control Tower
Integration with all MOM, ERP, IoT systems, and BI platforms
Centralized command center for global decision-making
Geprom’s industrial control tower collects data from MES, SCADA, ERP, and IoT sensors to provide a unified view of the entire factory or group of plants. It is the top layer of operational intelligence, ideal for multi-plant environments and distributed processes.
- Integration with MES, SCADA, ERP, IoT, sensors, and external devices
- Creation of personalized dashboards, accessible from any device
- Real-time decision-making based on cross-referenced data
- Global orchestration of processes, plants, and systems
- Automation of decisions based on operational rules
Success Stories
Our Clients
What our Clients Say
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“This project is a commitment to innovation that will allow us to evolve our business and thus guarantee the authenticity and quality of our tobacco. With Telefónica Tech’s traceability solution, we comply with European regulations on tobacco products and achieve comprehensive control and monitoring.”
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“The digital transformation project that we are starting aims to improve each and every one of the company’s processes, adapting to the new technological environments to achieve the highest level of effectiveness and efficiency at the Fini Company”
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“Measuring, controlling, and reducing the costs of bottling and storage processes is our challenge in a highly competitive environment with companies in the sector and declining consumption in all markets. Decisions regarding both processes, along with those related to quality, must be precise to offer the best service, and thus differentiate ourselves from our competitors.”
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“The IoT4DigitalTwin project, developed in consortium with Geprom and Gefasoft, has allowed us to incorporate the most advanced technologies of Industry 4.0, is bearing fruit, and represents an advance in boosting our competitiveness and efficiency.”
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“With the collaboration of Geprom and its GeTag platform, we have boosted the efficiency of our processes by centralizing business information and improving the customer service we offer.”
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“Through the technology consulting sessions, they outlined the implementation of Industry 4.0, indicating not only the areas for improvement that we were seeking, but also other improvements that will help us enhance our production and our work system.”
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“Proactively deploying a pilot test of the MES Objective system allowed us to verify the reduction of unnecessary costs to a minimum and allowed us to assess the investment in detail.”
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“Objective’s technical support service demonstrates its excellent knowledge time and again, available 24 hours a day”
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“In MES, master data can be fantastically integrated with production lines to eliminate paper on the factory floor. Furthermore, always having the correct data available is a necessity in our sector.”
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“The collaboration with Objective is very pleasant. The combination of Objective’s technical solution and Modiform’s experience has led to new ideas and developments that we now see again in the new version of Objective.”
The Digital Maturity Pyramid
What Level of Digital Maturity Does this Product Cover?
Geprom’s Industrial Predictive Maintenance is located in Level 5 of the Digital Maturity Pyramid (ISA-95).
At this level, organizations advance from operational digitization (continuous capture and visualization of equipment condition data) to integrated production management, where real-time data is combined with predictive algorithms to anticipate failures and optimize maintenance planning.
This level implies:
- Continuous capture of critical variables (vibration, temperature, cycles, consumption, etc.) from IoT sensors, SCADA, MES or PLCs.
- Early identification of patterns and anomalies using Machine Learning models.
- Generation of automatic alerts and recommendations to intervene before a failure occurs.
- Integration with CMMS and MES systems for the automatic creation of work orders and improvement of operational efficiency.
Still Have Questions?
Still have questions? Contact us and our team will be happy to help.
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