AI powered Predictive Maintenance

BMW

Location: Munich, Germany

Business: Builds EV battery components with 300 advanced machines.

Problem

Voltage spikes in assembly robots cost €2.5 million annually, with 25% of downtime linked to unpredictable electrical faults.

Approach

We worked directly with BMW’s robotics team, experimenting with real time electrical signal analysis, a technique adapted from aerospace projects.

Custom Solution

Created a MonkeyVision Predict setup with 120 current sensors and 30 cameras, crafting a bespoke AI model to detect voltage anomalies at 98% accuracy, integrated with BMW’s control system.

Implementation

4-week diagnostic with robot logs
12-month model development
Deployment on 50 machines
Trained 25 engineers
Fine-tuned over 6 months

Results

45%

Downtime drop
(€1.125 million saved)

25%

Reduced repair costs
(€625,000/year)

22%

Efficiency increase

97%

Fault prediction accuracy

“AI Monkeys’ electrical expertise transformed our robot reliability.”
– Robotics Supervisor, BMW Manufacturing