Longevity in industrial equipment isn’t just a goal — it’s the holy grail. Every company wants their machines to last as long as possible. But extending asset lifespans is far easier said than done.
Between relentless wear and tear, surprise breakdowns, and expensive repairs that never seem to end, keeping equipment in top shape can feel like a constant battle. For many, there is tremendous pressure to balance immediate fixes with long-term solutions, all while trying to make the most of every machine. And with aging equipment and increased operational demands, maintaining that balance only becomes tougher.
Many companies still rely on a reactive, or run-to-failure (RTF), strategy despite the well-known risks of operational disruptions and higher costs. Some facilities attempt to mitigate these risks by following scheduled maintenance based on estimates or original equipment manufacturer (OEM) guidelines, while others use statistics-based programs tailored to each asset. Even those leveraging continuous monitoring technologies may still rely on univariate analysis, where individual signals are monitored in isolation. This narrow focus often misses the bigger picture, leaving complex, underlying issues undetected.
As a result, all these strategies force companies into reactive firefighting rather than strategic growth. It’s a cycle that drains resources and limits the ability to invest in long-term solutions. Staying reactive means staying behind — but Azima DLI offers a smarter way forward.
Azima’s predictive maintenance solutions turn your equipment into its own safeguard. Sensors track every critical vibration and fluctuation, capturing even the smallest changes, which allows for early, proactive intervention. When combined with advanced diagnostics and expert systems that tackle complex, asset-specific issues, it’s as if your equipment can diagnose itself and warn you when to take action. Azima can detect most machine faults automatically, and for more challenging diagnostics, trained specialists are available around the clock to offer deeper, more nuanced analysis.
What sounds like something out of sci-fi is today’s reality. And it’s saving customers money while making the most of asset lifespans.
How Azima Works
To understand how Azima provides superior maintenance ROI, let’s dive into how the program works. It’s not just about gathering data; it’s about transforming that data into actionable insights that keep your equipment running smoothly. Here’s how it all comes together:
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Data Collection
Azima’s sensors provide around-the-clock measurements of your equipment’s critical health indicators, such as vibration and temperature, enabling real-time data access. This steady stream of information gives you an up-to-the-minute view of how your machines are performing.Azima’s suite of tools includes:
- The TRIO portable vibration data collector, which provides field teams with a flexible and efficient way to gather data.
- The Accel 310 wireless sensor, which is designed to offer accurate, wireless data collection in more challenging environments.
- The online VibGuard system, which enables advanced condition monitoring of highly dynamic critical assets.
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AI-Powered Diagnostics
Once Azima sensors collect enough data, the diagnostic engine takes over. It can analyze vibration data from wireless sensors on most rotating machine types, beyond just balance-of-plant equipment. This includes data from portable devices for complex or standard routes and online systems for hard-to-access and critical applications.
Trained on 30 years of operational data, the system uses AI to draw from 100 trillion data points across 50 different machinery component types. It locates useful details for each application (such as gear-mesh frequencies, vane counts on pumps, and rotor bars on motors) to analyze incoming data. Finding data patterns allows Azima to diagnose early warning signs of equipment failure.
Based on this analysis, Azima provides detailed, prescriptive maintenance recommendations to address the identified issues. These insights are highly tailored to each machine’s operational environment, factoring in things like typical load, usage frequency, and historical performance.
For example, if the system detects early signs of bearing wear, it might recommend lubrication to prevent further degradation. In more severe cases, it could recommend a “Mandatory” priority repair status—such as “Mandatory Replace Motor Bearings”—indicating that immediate action is required to avoid potential failure. With these customized recommendations, technicians can confidently take recommended actions early and plan maintenance strategically.
Importantly, Azima’s system also performs root cause analysis. It doesn’t just stop at detecting the problem — it digs deeper to identify the underlying causes of failure. This means that your maintenance strategies can be adjusted and improved over time, targeting the real issues rather than just addressing symptoms. By understanding what’s causing the wear or failure, you can fine-tune processes to reduce recurrence and optimize overall performance and equipment longevity. -
Expert Analysis
Our analysts work in tandem with Azima’s diagnostic system to provide a synergy that enables unparalleled excellence in machine diagnostics.
93% of the data processed by our diagnostic engine doesn’t need human intervention — the AI handles it with remarkable precision. But for the more complex 7%, Azima’s team of certified vibration analysts, trained to ISO Level II-IV standards, step in to provide the necessary context and insight. They bring years of experience to the table, conducting diagnostics on more than 1,000,000 machine tests each year. This means they can help interpret results in practical terms, guiding you on whether immediate action is required or if routine maintenance can suffice.
This balance between advanced technology and human oversight means that you’re not just relying on machines to spot problems — you’re getting the benefit of decades of industry experience to make the best decisions for your equipment.With Azima’s predictive maintenance solutions and data analysis, you have the ability to turn potential disasters into manageable fixes. No more waiting for things to break; instead, you’re always a step ahead, knowing what your machines need before they do.
Real-World Success with Azima
Azima’s predictive maintenance solutions aren’t just theoretical — they’ve been delivering real results for decades across industries like food and beverage, oil and gas, power, and mining. These solutions help companies extend the lifespans of critical assets and avoid costly breakdowns.
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How Azima Helped Extend Asset Life at a San Juan Mine
When a longwall coal mining facility partnered with Azima, they implemented a hybrid predictive maintenance program using TRIO hardware and the reliability portal backed by the expertise of Azima’s vibration analysts.This success was due, in particular, to Azima’s proprietary diagnostic Impact Demod algorithm, which sifts through the background noise common in mining operations. The primary advantage lies in its ability to process data in a way that identifies failures long before traditional spectral analysis would. It is especially effective for detecting faults in slow-rotating machinery, which conventional methods struggle to monitor.
The first fault Azima analysts caught indicated elevated harmonics on a drive motor gear pulley in the coal processing plant. The pulley also showed impacting at the head roll coupled-end bearing. The increased speed of the head roll indicated a serious-to-extreme bearing fault. Thanks to this quick catch, mine personnel were able to schedule repairs before the issue escalated.
The second key discovery involved an underground conveyor, where Azima’s diagnostics revealed that water and coal damage had caused bearing wear. Early detection of this problem allowed the mine to implement targeted adjustments — such as upgrading components and refining lubrication practices — effectively preventing future breakdowns and extending the operational life of the conveyor system.
If left undetected, these two faults would have cost the mine more than $100,000 in repair expenses and lost productivity.
- How Azima’s Predictive Maintenance Saved the U.S. Navy Millions
In high-stakes naval operations, equipment longevity isn’t just about cost savings — it’s about mission success and safety, too. When a U.S. Navy fleet adopted Azima’s predictive maintenance program, it gained a powerful tool for extending the operational life of critical assets.During a routine machine condition analysis survey conducted on a vessel by Azima with the assistance of the ship’s crew, a moderate issue was identified in the intermediate shafting of a main propulsion reduction gear. The initial detection highlighted abnormal harmonics that indicated a developing fault. Three months later, the crew collected additional data, which showed that the issue had escalated to a “serious” fault level. Then, another three months of data collection revealed the fault had worsened to an “extreme” level, signaling imminent failure.Thanks to Azima’s early detection, the ship’s maintenance personnel were on high alert and able to act during a scheduled repair period at the shipyard. They discovered a serious crack in one of the high-speed driven gears and replaced it. A post-repair vibration test indicated good machine condition and no faults.Had the fault been left unchecked, it could have led to catastrophic gearbox failure, grounding the vessel for weeks and requiring extensive and costly repairs. Such a fix would have included cutting into a major access area on the side of the ship. Furthermore, it was estimated that the total cost saved was upwards of eight to ten million dollars — approximately equal to the cost of the Navy’s machinery condition analysis program for a whole fleet of a dozen ships for a decade.
The real-world proof of Azima’s impact is in the numbers: fewer failures, longer equipment life, and millions saved. And that’s the difference Azima makes every single day.
Conclusion
There’s a saying that goes, “If you’re not moving forward, you’re moving backward.” To keep your company on the cutting edge of production, you need solutions that continually improve your maintenance program — not just keep the status quo.
Azima proves that the best way to manage equipment isn’t by waiting for something to go wrong. It’s about being proactive and knowing when to take preventive action. Rather than reacting to breakdowns, companies can anticipate them with data and advanced diagnostics. The result is unmatched foresight to plan smarter, act sooner, and give critical assets a new lease on life.