- In the Industry 4.0 era, predictive maintenance faces challenges such as data integration, interoperability, and scalability. However, these challenges also present opportunities for leveraging AI and IIoT technologies to revolutionize maintenance strategies.
- Nanoprecise’s founder and CEO, Sunil Vedula, says both efficiency and maximum uptime of machinery can be achieved by automating the collection of quality data and ensuring automated data analysis (using both AI and the physics behind machinery) to get accurate results. Further, maintaining machines to address faults that consume excess energy is a great benefit for maintenance technicians, achieving energy savings in addition to reduced downtime.
- Vedula says, “We see an opportunity to leverage Artificial Intelligence and IIoT technology to reduce global carbon emissions by 5 – 10%.”
Predictive maintenance is a key component of Industry 4.0, the fourth industrial revolution that integrates digital and physical systems. It prevents equipment failures and optimizes maintenance schedules by using data-driven insights and predictive analytics.
Predictive maintenance, however, has challenges. Data integration, interoperability, and scalability are major hurdles to effective and efficient maintenance solutions. Moreover, material failures can devastate the environment, safety, and profitability of industrial operations.
Nanoprecise, an advanced predictive maintenance solution provider, specializes in creating innovative solutions for predictive asset maintenance using artificial intelligence (AI) and industrial Internet of Things (IIoT) technologies. Sunil Vedula, Nanoprecise’s founder and CEO, says, “Nanoprecise uses AI and IIoT to provide real-time data analysis, enable proactive decision-making, and minimize downtime. IIoT sensors provide a wealth of data for predictive analytics, allowing for precise and timely maintenance interventions.”
Mirror Review recently interviewed Sunil, who shared how Nanoprecise transforms predictive maintenance with AI and IIoT and why it is one of the Top 10 innovative software development companies of 2024.
(The following Q&A has been edited for length and clarity.)
Mirror Review: Briefly share the origin story of Nanoprecise Sci Corp. What problem are you trying to solve with your software solutions?
Sunil: Nanoprecise was born in 2018 as a company offering high-quality material failure analysis services. After analyzing failures of different materials, we discovered that most of these failures could have been avoided if there had been a way to properly collect and analyze data on the deformation or degradation of the materials before they reached a critical point.
We saw a huge potential for predicting such failures for rotating machinery, such as pumps, motors, compressors, etc., before they happened and worked hard and continuously innovated to combine physics with data analytics and reliability to create a breakthrough product.
Meanwhile, we also became aware of the wider implications of our work for society and the environment. We saw an opportunity to leverage artificial intelligence and IIoT technology to reduce global carbon emissions by 5–10 percent by prescribing the right maintenance on the right equipment at the right time. In doing so, we also helped avoid production losses due to unplanned downtime in the process. Basically, we achieved two massive objectives (production + efficiency = sustainability) with one solution.
Mirror Review: Nanoprecise is known for its cutting-edge predictive maintenance software. Could you please elaborate on the unique features and technologies that set your solutions apart from competitors?
Sunil: Our solutions are designed to offer the best value to our customers in terms of ease of installation and use, wireless connectivity, real-time insights, hazardous area certification, edge monitoring, advanced data analysis, comprehensive monitoring, and user-friendly dashboard. Let me explain each of these features in more detail.
- Ease of Installation and Use: Our products, MachineDoctor and NrgMonitor, are designed to be installed and integrated into industrial environments within five minutes, with a user-friendly interface and seamless functionality.
- Wireless Connectivity: The MachineDoctor sensor operates on cellular networks (3G/4G/5G) using an e-SIM, which enhances its accessibility and coverage. It does not require any complex wiring or network infrastructure while maintaining a high level of communication security.
- Real-Time Insights: MachineDoctor measures six critical parameters—vibration, acoustic, speed, magnetic flux, temperature, and humidity—providing comprehensive real-time insights into the health and performance of industrial assets.
- Hazardous Area Certification: MachineDoctor holds ATEX and IECEx Zone 0 certification, making it suitable for use in hazardous industrial environments, such as oil and gas, mining, chemical, and power generation.
- Edge Monitoring: MachineDoctor sensor has advanced edge processing capability that facilitates enhanced real-time monitoring without full-time connectivity.
- Advanced Data Analysis: Our integrated solution employs advanced signal processing algorithms (CEEMDAN) to detect even small changes in machine performance, well before they lead to unplanned downtime. It also provides real-time alerts and reports to the maintenance team, thereby facilitating accurate decision-making.
- Monitoring Energy Efficiency: Our AI-based solution tracks energy efficiency along with condition monitoring of motor-driven equipment, allowing manufacturers to optimize their overall operational efficiency.
- User-Friendly Dashboard: Our dashboard has an intuitive design for easy navigation and quick access to critical information. It provides real-time updates on energy consumption, health analytics, and machine conditions, ensuring users have the latest information at their fingertips. It also ensures accessibility across multiple devices and platforms, enabling users to monitor and manage operations seamlessly from anywhere. Moreover, the responsive design facilitates a consistent and user-friendly experience on desktops, tablets, and mobile devices.
Mirror Review: Which industries do you primarily target? How does Nanoprecise tackle its predictive maintenance challenges?
Sunil: Our customers come from a wide range of industries, such as automotive, chemicals, cement, consumer electronics, forestry, HVAC, metals, mining, and oil and gas. However, regardless of their sector, they all share a common need: to optimize their manufacturing processes and reduce downtime. Therefore, we enable them to start their Industry 4.0 journey with a relatively small budget focused on key goals while laying the foundation for IIoT implementation at scale. Meanwhile, we focus on providing customized solutions that integrate seamlessly with existing infrastructure, ensuring a smooth transition to predictive maintenance practices.
With our state-of-the-art hardware and patented software, we have been driving the digital transformation of the manufacturing process for companies across the globe. Our advanced AI sends notifications to customers, alerting the maintenance teams about anomalies and faults in different machines across different sectors, thereby empowering them with the right data at the right time.
Mirror Review: Could you elaborate on the 360° integrated systems you develop and their ability to predict the remaining useful life of assets with 99% accuracy?
Sunil: Sure. Our solution offers a 360° integrated system by combining data from our 6-in-1 sensors and asset specifications, which create a holistic view of asset health. The predictive accuracy of 99% is achieved through the synergistic use of AI algorithms, historical data analysis, and real-time sensor data. This comprehensive approach not only enables us to understand the current machine health but also to accurately forecast the remaining useful life of assets, optimizing maintenance schedules and resource allocation. By doing so, we help our customers improve their operational efficiency and reduce their costs.
Mirror Review: How do you measure the tangible benefits your clients gain in terms of cost reduction, efficiency improvement, carbon footprint reduction, and downtime minimization?
Sunil: By using our solution, our clients can achieve substantial savings in maintenance costs, increased operational efficiency, reduced environmental impact, and minimized downtime. All of these factors contribute significantly to a higher return on investment. We can quantify the ROI by looking at the downtime and production loss avoided, the potential damage to the machine and overages in energy consumption (sometimes as high as 15 %), and the negative impact on the carbon footprint for the organization. Moreover, the platform itself calculates and displays the latter two, helping to drive maintenance teams to a more energy-centered maintenance practice. This way, we help our clients save money and protect the environment.
Mirror Review: Your team is recognized as a leader in AI and IIoT development. Can you tell us about your company culture and any particular projects, partnerships, or recent achievements you’d like to spotlight?
Sunil: At Nanoprecise, we foster a culture of innovation and collaboration. Our team is motivated by the opportunity to pioneer advancements in AI and IIoT, which have a transformative impact on industries. We encourage a dynamic and supportive environment that values creativity, continuous learning, and a shared commitment to pushing the boundaries of technology.
As the leader of Nanoprecise, my key roles involve driving the overall vision, strategy, and growth of the company. I foster partnerships, oversee innovative projects, and ensure our solutions align with industry needs.
One notable achievement that I am proud of is the recent strategic partnership with Henkel Adhesive Technologies, a global leader in adhesives, sealants, and functional coatings. The Henkel partnership is a significant milestone, as it reinforces our commitment to advancing industrial operations through digitalization.
This collaboration aims to promote sustainability and operational excellence in manufacturing. The partnership represents a union of industry expertise and technological advancement, both of which are committed to revolutionizing industrial operations and achieving greater levels of equipment maintenance and reliability.
Together, Henkel and Nanoprecise Sci Corp are reshaping the future of smart and efficient operations in the process industries. This partnership presents a significant opportunity to steer industries toward a more sustainable and eco-friendly future.
Mirror Review: What are your future objectives for Nanoprecise Sci Corp? Are there any new markets or sectors you’re planning to penetrate?
Sunil: As the leader in predictive maintenance and energy efficiency monitoring, we are always looking for new ways to innovate and expand our reach. The future of these technologies is poised for significant advancements, and at Nanoprecise, we are committed to leading this transformative journey. We anticipate a future in which these technologies are integral to industrial operations, and our focus is on staying at the forefront of this paradigm shift.
In the next few years, we expect real-time insights to become the standard. Nanoprecise is poised to pioneer this evolution by providing immediate actionable insights to our customers, empowering them to make well-informed decisions promptly. We are constantly researching and developing new solutions that offer precise predictions for optimized asset maintenance.
We also recognize the growing significance of edge computing and we are investing in bringing more intelligence to the edge. This entails enhancing AI capabilities at the edge to detect anomalies and faults, triggering swift notifications. Our goal is to provide even quicker responses to critical situations, ensuring minimal disruptions and improved reliability. We want to democratize these technologies and make predictive maintenance and energy efficiency accessible to every plant.
Moreover, we are aligned with global sustainability goals and are dedicated to reducing carbon footprints through energy optimization. We are actively working on user-friendly solutions tailored for a wide range of industries, and we aim to make predictive maintenance and energy efficiency monitoring attainable for all. We have a vision of global expansion, collaborating across regions to enhance operational efficiency, minimize downtime, and champion environmental sustainability.
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Also Read: The 10 Innovative Software Development Companies, 2024
