Case Study: Heavy-Duty Trucks and Engines Manufacturing Company achieves reduced downtime and 5% lower warranty costs through real-time engine monitoring with Cognizant

Reduce Downtime With Real-Time Engine Monitoring

Cognizant worked with a manufacturer of heavy‑duty truck engines that faced costly, time‑consuming failures when vehicles broke down in remote locations. The company’s reactive service model—customers only called after a failure—caused up to three weeks of downtime, lost revenue and high warranty costs, so it needed a remote monitoring and predictive maintenance solution.

Cognizant integrated telematics with a big‑data analytics platform to assess engine health in real time and flag potential failures; customers and nearby service centers receive near‑real‑time fault notifications and repair instructions. The program enabled proactive maintenance of about 20K faults per month across 150K engines and delivered a 5% year‑over‑year reduction in warranty costs.