Predictive Maintenance Case Study for a Packaging Plant in Faridabad

The plant was facing repeat stoppages on drive-heavy line equipment and had no structured way to rank which warnings needed early maintenance action.

The plant moved from reactive breakdown handling to a structured maintenance review process that improved line stability without a full greenfield rebuild.

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Predictive maintenance case study for packaging plant equipment

Client Packaging plant in Faridabad

Industry Flexible packaging

Challenge

The plant was facing repeat stoppages on drive-heavy line equipment and had no structured way to rank which warnings needed early maintenance action.

Solution

We mapped PLC runtime, alarms, drive faults, and maintenance records to build a focused monitoring and intervention plan for the most failure-prone machines.

Technologies Used

PLC diagnostics
SCADA trend history
Drive fault logs
Machine health dashboards

Implementation Steps

Selected the top downtime-contributing assets
Mapped fault patterns and operator intervention history
Configured a review dashboard for maintenance supervisors
Defined escalation rules for high-risk operating behavior

Results

31% reduction in repeat stoppages on prioritized machines
Faster maintenance response to developing faults
Improved spare planning for recurring failure points

Project Impact

The plant moved from reactive breakdown handling to a structured maintenance review process that improved line stability without a full greenfield rebuild.

Need Similar Results on Your Plant or Machine Line?

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