RevUptime / SolutionsA LAYERED APPROACH TO RELIABILITY

Match monitoring depth to machine risk.

Start with critical assets, extend sensor coverage to fit the plant, and help teams rank the work that needs attention.

SOLUTION TIERS

Three layers. One maintenance workflow.

Each layer adds context to how a plant monitors, investigates and prioritises equipment.

01 · AI SHIELDS

Equipment-specific AI

Apply equipment-specific analysis to critical assets where an unexpected stop carries the greatest operational risk.

  • Kilns, mills, cranes, furnaces, fillers and run-out tables
  • Dynamic FMEA to structure fault analysis
  • 24×7 human expert review
02 · FLEX RELIABILITY

Flexible plant coverage

Extend condition monitoring across the rest of the plant using the sensing approach that fits each asset.

  • Wired piezoelectric or MEMS sensors
  • Wireless self-powered monitoring tags
  • Ingest existing third-party sensor data; no rip-and-replace
03 · PLANT FUSION

Risk-based plant ranking

Rank what to maintain, stock and replace by risk, and share the resulting context with enterprise systems.

  • Risk-based ranking using RBI, RCM and FMEA
  • Prioritised maintenance, spares and replacement planning
  • Open API and MCP feed for enterprise systems
FAILURE MODE COVERAGE

Equipment-borne and process-induced modes.

RevUptime’s failure-mode framework covers 20+ modes in each family. These selected examples show why condition signals need to be interpreted with machine and process context.

20+ EQUIPMENT-BORNE MODES

Faults in the asset or its components

Mechanical condition changes associated with bearings, rotating forces, fits, lubrication and drive components.

  • Bearing wear
  • Unbalance
  • Misalignment
  • Looseness
  • Cavitation
  • Resonance
  • Lubrication degradation
  • Gear-mesh anomalies
Signals + context
20+ PROCESS-INDUCED MODES

Process conditions affect performance

Changes driven by thermal, material, flow or production behaviour across specific industrial processes.

  • Kiln ring formation
  • Thermal overstress
  • Cyclone coating build-up
  • Ladle heat drift
  • Hot-strip thermal fatigue
  • Web tension drift

Examples are not a complete mode list or an automatic diagnosis. Detectability depends on installed sensors, signal quality, operating context and site validation. Confirm suspected causes with qualified personnel and site procedures.

START WITH YOUR CRITICAL ASSETS

Build a monitoring plan for your plant.

Review asset suitability, operating context and pilot priorities with the RevUptime team.

Discuss your plant