In an era where competitiveness relies heavily on the reliability and responsiveness of equipment, using AI to predict industrial failures has become a strategic necessity. By analyzing machine data in real time, solutions like LESLY, developed by Dianalyse, help avoid unplanned downtime, extend component lifespan, and optimize maintenance with unprecedented precision.
Why the Industry Is Betting on Artificial Intelligence
According to a Capgemini study, 29% of industrial companies already use AI in their operations, and this figure exceeds 50% in sectors like automotive and energy. And with good reason:
AI can reduce maintenance costs by 10 to 40%
Improve machine availability by 10 to 20%
And cut breakdowns by up to 50% through early anomaly detection
These numbers reflect a major shift. Where maintenance was once reactive, it is now predictive—or even prescriptive—thanks to automated analysis of complex data.
Using AI to Predict Industrial Failures: A Proactive Approach
LESLY embodies this new era. By combining unsupervised artificial intelligence with advanced signal processing, the solution identifies abnormal behavior long before breakdowns occur.
Its AI engine autonomously learns each machine’s normal operation patterns. From there, even the slightest deviation is detected, classified, and interpreted as an alert. This is known as predictive anomaly detection based on weak signals.
In concrete terms, this approach leads to:
A 20% reduction in scrap caused by undetected machine drift
A 30% increase in component lifespan
And up to a 40% improvement in machine availability
AI in Industrial Maintenance: A Powerful Operational Lever
AI-driven predictive maintenance relies on three key pillars:
Continuous data collection from sensors (vibration, temperature, pressure, current, etc.)
Intelligent analysis by algorithms that detect early warning signs
Clear visualization of anomalies and risks to guide human action
With LESLY, this process is smooth and requires no data scientist. Field teams have access to an intuitive interface that lets them anticipate critical incidents and schedule interventions at the right time—not too early, not too late.
This strategy helps reduce:
The costs of unplanned downtime (lost production, emergency repairs)
Pressure on maintenance teams, who can work more predictably
The need for excessive spare part stock, thanks to accurate residual life estimation
Embedded AI and Immediate ROI: The LESLY Advantage
Unlike cloud-based solutions requiring heavy infrastructure, LESLY runs on a simple industrial PC. This ensures:
Quick on-site installation
Centralized monitoring of all machines across a network, even with mixed brands
And most importantly, a measurable return on investment within weeks
Conclusion: Smarter Maintenance, Stronger Industry
Using AI to predict industrial failures is no longer futuristic—it’s practical, profitable, and accessible. With tools like LESLY, manufacturers can turn raw data into informed decisions, reduce unplanned downtime, and extend the life of their assets.
Artificial intelligence doesn’t replace humans—it empowers them. It gives technicians, maintenance managers, and plant directors the ability to take control of uncertainty, making maintenance a true driver of long-term performance.
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