V13 · Industry & Operations
Industrial Process & Equipment Monitoring
← Back to Industry & Operations clusterUnplanned downtime costs industrial operations $50B+ annually.
Equipment doesn't fail randomly — it degrades predictably if you're measuring
the right things. Process quality is the same: defects have precursors.
Sensor→
Ingest→
Interpret→
Decide→
Act→
Outcome→
Learn↩
Data In — Sensors
- Vibration (accelerometer, velocity transducer) — bearing, gear, motor, pump, fan, compressor
- Temperature (thermocouple, RTD, IR pyrometer) — bearings, motors, process, furnace, kiln
- Pressure (process, hydraulic, pneumatic, vacuum, steam)
- Flow (liquid, gas, steam — mag, ultrasonic, vortex, Coriolis, orifice)
- Motor current / power (current signature analysis for motor health)
- Oil analysis (online particle counter, moisture, viscosity)
- Ultrasonic (thickness for corrosion/erosion, leak detection)
- Torque (shaft, bolt, mixing)
- Speed / RPM (proximity probe, encoder, tachometer)
- Displacement (shaft position, radial/axial)
- Strain (structural, equipment frame)
- Level (tank, hopper, silo — radar, ultrasonic, guided wave, weight)
- Conveyor belt condition (rip detection, belt scale, alignment)
- Valve position / actuator status
- Compressed air (pressure, flow, dew point, leak detection)
- Steam quality (pressure, temperature, dryness fraction)
- Quality sensors: vision (defect detection), dimensional (laser/gauge), weight, color, surface finish, moisture, hardness
Interpret — What the AI does with it
- Vibration spectral analysis: bearing defect frequencies (BPFO, BPFI, BSF, FTF), imbalance, misalignment, looseness, gear mesh
- Temperature trend: gradual rise on bearing = lubrication issue, sudden rise = imminent failure
- Motor current signature: broken rotor bar, eccentricity, load variation
- Process parameter correlation: which combination of temperature + pressure + speed produces quality output?
- OEE calculation: availability × performance × quality from sensor data
- Remaining useful life estimation: degradation curve extrapolation
- Quality prediction: process parameters → predicted product quality (before inspection)
Decide & Act — The decision rules
- Early fault detected → Schedule maintenance at next planned stop (avoid unplanned downtime)
- Imminent failure → Emergency shutdown, alert maintenance, order parts
- Process drifting from quality window → Adjust parameters, alert operator
- Compressed air leak detected → Create maintenance work order, quantify energy waste
- Conveyor belt rip → Emergency stop, alert maintenance
- OEE dropping below target → Root cause analysis suggestion, alert production manager
Outcome & Learn — Closing the loop
- Predicted failure vs. actual failure date (improve RUL models)
- Maintenance performed: did vibration return to baseline? (Repair quality)
- Quality prediction accuracy: process parameters → product quality correlation
- Which failure modes produce the most downtime? (Prioritize monitoring)
Industries Served
- Manufacturing (discrete + process — automotive, electronics, food, chemical, paper, plastics)
- Oil & gas (pumps, compressors, separators, wellhead equipment)
- Mining (crushers, conveyors, mills, haul trucks, draglines)
- Power generation (turbines, generators, transformers, boilers, cooling towers)
- Water / wastewater (pumps, blowers, UV systems, chemical feed)
- Pharmaceutical (reactors, mixing, clean utility, filling lines)
- Food & beverage (cooking, mixing, packaging, CIP, pasteurization)
- Cement / aggregates (kilns, grinding mills, conveyors, crushers)
- Steel / metals (furnaces, rolling mills, casting, heat treatment)
- Pulp & paper (paper machines, recovery boiler, digesters)
- Petrochemical / refining (distillation, cracking, reforming)
Regulatory Frameworks
Coming soon.
Transport
Serial/Modbus/HART (legacy equipment), MQTT, Reticulum (shop floor mesh where wiring is impractical), OPC-UA
Deploy Industrial Process & Equipment Monitoring today
Start free with Scout — 5 edge agents, 10K events/month. Scale when you need to.
All tiers available for this vertical.
Scout is free forever (5 agents, 10K events/mo). Hive is $299/mo. Swarm is $999/mo. Colony is custom.
Bundle discount: 20% off when paired with an active midmen.ai or augmen.app subscription.
Scout
Free
5 edge agents · 10K events/mo
MQTT + HTTP transport
Community support
MQTT + HTTP transport
Community support
Hive
$299/mo
50 edge agents · 500K events/mo
All transports
Email support
All transports
Email support
Swarm
$999/mo
500 agents · 10M events/mo
All + fleet consensus
Priority support
All + fleet consensus
Priority support
Colony
Custom
Unlimited agents & events
Dedicated infrastructure
SLA + on-site
Dedicated infrastructure
SLA + on-site