AI powered Predictive Maintenance

Thyssenkrupp Automotive

Location: Lemington Spa, Germany

Business: Manufactures chassis systems with 200 heavy-duty machines.

Problem

Wear on hydraulic presses led to £1.8 million in yearly breakdowns, with manual inspections missing early wear signs.

Approach

I led a team to analyze press cycles, introducing high-speed video analysis to capture wear progression, a method we pioneered for this project.

Custom Solution

Built a MonkeyVision Predict system with 100 high-speed cameras and 50 pressure sensors, developing a wear-prediction algorithm tailored to Thyssenkrupp’s presses, achieving 97% accuracy, linked to their maintenance logs.

Implementation

3-week equipment audit
10-month algorithm tuning with press data
Rollout on 40 machines
Trained 18 technicians
Optimized over 5 months

Results

40%

Breakdown reduction
(£720,000 saved)

20%

Lower repair costs
(£360,000/year)

18%

Efficiency boost

96%

Wear detection accuracy

“AI Monkeys’ innovative video analysis saved our press line.”
– Maintenance Head, Thyssenkrupp Automotive