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MANUFACTURING

Reduce Downtime With Real-Time Engine Monitoring

The Challenge

This manufacturer of engines for heavy-duty trucks needed to prevent failures that could result when vehicles running its engines are exposed to the severe stresses of traveling across remote locations. Any engine failure causes significant customer downtime (up to three weeks), depending on parts availability and workload, which leads to loss of revenues. 

The old service process for the manufacturer’s engines involved customers calling the service center to book appointments only after a failure resulted in downtime. This reactive process crippled operations and increased customers’ costs. The company contacted Cognizant for a solution that would provide its customers remote monitoring and predictive maintenance services.

Our Approach

Cognizant’s solution integrates a telematics service to capture data originating in the manufacturer’s engines. A sophisticated big data and analytics solution then assesses that data to determine the health of each engine and identify potential points of failure. If a possible malfunction is detected, customers receive a notification about it, along with instructions on how to reach the nearest service center. That service center gets a similar notification about the incoming vehicle and possible root cause of the problem. This approach enables proactive, timely fault repair.

Real Results From Real-Time Monitoring

5% year over year

reduction in warranty costs with real-time fault detection

Proactive maintenance

of approximately 20K faults per month in 150K engines

Near-real-time

fault code messages sent to customers

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