AI powered Predictive Maintenance

McLaren Motors (UK)

Location: Woking, Surrey, UK

Business: Produces high-performance supercars with 120 precision machines.

Problem

Overheating in carbon fiber molding units caused £1.2 million in annual delays, with inconsistent temperature data complicating maintenance.

Approach

We spent weeks on-site, collaborating with McLaren’s engineers to map heat patterns, using thermal imaging alongside traditional sensors.

Custom Solution

Designed a MonkeyVision Predict variant with 60 thermal cameras and 20 vibration sensors, training a custom neural network on McLaren’s thermal data to predict overheating 94% accurately, integrated with their production software.

Implementation

2-week site analysis
4-month data modeling
Deployment on 30 machines
Trained 12 staff
Refined over 3 months

Results

30%

Fewer delays
(£360,000 saved)

15%

Reduced energy costs
(£180,000/year)

10%

Efficiency gain

90%

Early detection of heat issues