Case Study: Metals Company avoids downtime and anticipates failures with Falkonry Time Series AI

How Falkonry Helped Anticipate Failures & Avoid Downtime

A metals company was facing production losses, higher expenses, and unplanned downtime due to failures of key components in its continuous steel casting process, such as the pinch rolls. The challenge was to get sufficient advance warning of these failures to avoid costly downtime and high maintenance repair costs. The company turned to Falkonry for a solution.

Using its Time Series AI, Falkonry analyzed the company's existing sensor data to automatically detect deviations from normal operations. The system provided alerts up to seven days before a pinch roll was predicted to fail, along with explanations of the contributing signals. This allowed reliability engineers to take proactive action. The solution helped avoid unplanned downtimes that cost an estimated $9,000 per hour, preventing losses of over $2 million per production line annually.